SECTION 200

SITE CLEARANCE

200.1 SPECIFICATIONS FOR CLEARING AND GRUBBING

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

200.1.2 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 300.6. Before start of operations, the contractor shall submit to the
engineer for approval, his work plan including the procedure to be followed for disposal of
waste materials, etc., and the schedules for carrying out temporary and permanent
erosion control works as stipulated in clause 300.6.3.

200.1.3 Methods, tools and equipment - 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 roots,
under-growth, grass and other deleterious matter unsuitable for incorporation 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 1m 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.

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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.

Anti-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.

200.1.4 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 stacked.
Also boulders, stones and other materials usable in road construction shall be neatly
stacked as directed by the engineer. Stacking of stumps, boulders, stones, etc., shall be
done as specified spots with all lifts and upto a lead of 1000m.

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. Cash 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.

200.1.5 Measurements of payment - Clearing and grubbing for road embankment, drains
and cross-drainage structures shall be measured on area basis in terms of hectares.
Clearing and grubbing of borrow areas shall be deemed to be a part of works preparatory
of 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 trees upto 300 mm in girth including removal of stumps and roots
after obtaining prior clearance from the forest department/authorities 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 if 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

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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.

200.1.6 Rates
200.1.6.1. 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.

200.1.6.2. The contract unit rate for cutting (including removal of stumps and roots) of
trees of girth above 300 mm shall include excavation and backfilling to required
compaction, handling, salvaging, piling and disposing of the cleared materials with all lifts
and upto a lead of 1000 m.

200.1.6.3. Where a contract does not include separate items of clearing and grubbing, the
same shall be considered incidental to the earthwork items and the contract unit prices for
the same shall be considered as including clearing and grubbing operations.

200.2 SPECIFICATIONS FOR DISMANTLING CULVERTS, BRIDGES AND OTHER

STRUCTURES/PAVEMENTS
200.2.1 Scope
This work shall consist of removing, as hereinafter set forth, existing culverts, bridges,
pavements, kerbs and other structures like guard-rails, fences, utility services, manholes,
catch basins, inlets, etc., which are in place but interfere with the new construction or are
not suitable to remain in place recording of pre-measurements and check measurement
by competent officers and of salvaging and disposing of the resulting materials and back
filling and 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.

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200.2.2 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 overlaying 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 left in place so as to project into a
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 dismantled 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.

200.2.3 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 cum. and
stockpiled locations if the material is to be used later or otherwise arranged for disposal as
directed (see clause 200.2.5).
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200.2.4 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.

200.2.5 Disposal of materials - All materials obtained by dismantling shall be the

property of government. Unless otherwise specified, materials having any salvage 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 location suitable for loading.
Structures or portions thereof 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 off as directed by the engineer with all lifts
and upto a lead of 1000 m.

200.2.6 Measurements for payment - 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 timber structures cu.m
(v) Dismantling pipes, guard rails, kerbs, gutters and fencing linear m
(vi) Utility services Nos.

200.3 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 incidentals necessary to complete the work.
These will also include excavation 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.

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 SECTION 300

EARTH WORK, EROSION CONTROL AND DRAINAGE

300.1 SPECIFICATIONS FOR EXCAVATION FOR ROADWAYS AND DRAINS

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

300.1.2 Classification of excavated material

300.1.2.1 Classification - All materials involved in excavation shall be classified by the
engineer in the following manner:

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

(b) Ordinary rock (not requiring blasting) This shall include:

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

(ii) macadam surfaces such as water bound and bitumen/tar bound; soling of roads; paths
etc. and hard core; compact moorum or stabilised soil requiring grafting tool or pick or both
and shovel, closely applied; gravel and cobble stone having maximum 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 sand stone masonry in cement mortar below ground level; and

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

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(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 soils excavated from other areas
requiring continuous pumping or
bailing out of water.

300.1.2.2. Authority for classification - The classification of excavation shall be decided

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

300.1.3 Construction operations

300.1.3.1 Setting out - After the site has been cleared as per clause 201, the limits of
excavation shall be set out true to lines, curves, slopes, grades and sections as shown on
the drawings or as directed by the engineer. The contractor shall 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.

300.1.3.2 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 roots, with
approval of the engineer.

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300.1.3.3 Excavation – General - All excavations shall be carried out in conformity with
the directions laid here in under and in a manner approved by the engineer. The work
shall be so done that the suitable materials available from excavation are satisfactorily
utilized as decided upon beforehand.

300.11 While planning or executing excavations, the contractor shall take all adequate
precautions against soil erosion, water pollution etc. as per clause 300.6, and take
appropriate drainage measures to keep the site free of water in accordance with clause
300.11. The excavation 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 300.5

All debris and loose material on the slopes of cuttings shall be removed. No backfilling
shall be allowed to obtain 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.

300.1.3.4 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.

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

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Where excavation is done to levels lower than those specified, the excess excavation shall
be made good as per clauses 300.1.3.3. and 300.1.6 to the satisfaction of the engineer.
Slopes in rock cutting shall be finished to uniform lines corresponding to slope lines shown
on the drawings or as directed by the engineer. Notwithstanding the foregoing, all loose
pieces of rock on excavated slope surface , which move when pierced by a crowbar shall
be removed.

Where blasting is to be resorted to, the same shall be carried out as per clause 300.2 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 in clause 300.3.

300.1.3.6 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
staked by the engineer, and to the bottom of the marsh, firm support or levels indicated.

300.1.3.7 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. While doing so, care shall be taken to see that no portion of the existing
pavement designated for retention is loosened or disturbed. If the existing pavement gets
disturbed or loosened, it shall be dismantled and cut to a regular shape with sides vertical
and the disturbed/loosened portion removed completely and relaid as directed by the
engineer, at the cost of the contractor.

300.1.3.8 Excavation for surface/sub-surface drains - Where the contract provides for
construction of surface/sub-surface drains as in clause 300.9, excavation for these shall
be carried out in proper sequence with other works as approved by the engineer.

300.1.3.9 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.

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 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.

300.1.3.10 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 by 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.

300.1.3.11 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 embankment, (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.

300.1.3.12 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.

300.1.4 Plying of construction traffic - Construction traffic shall not use the cut
formation and finished subgrade without prior permission of the engineer. Any damage
arising out of such use shall be made good by the contractor at his own expense.

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300.1.5 Preservation of property - The contractor shall undertake all reasonable
precautions for the protection and preservation of any or all existing roadside trees, drains,
sewers or other sub-surface drains, pipes, conduits and any other structures under or
above ground, , which may be affected by construction operations and , which, in the
opinion of the engineer, shall be continued in use without any change. Safety measures
taken by the contractor in this respect shall be got approved from the engineer. However,
if any of these objects is damaged by reason of the contractor’s negligence, it shall be
replaced or restored to the original condition at his expense. If the contractor fails to do so,
within the required time as directed by the engineer or if, in the opinion of the 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.

300.1.6 Preparation of cut formation - The cut formation, , which serves as a sub grade,
shall be prepared to receive the sub-base/base course as directed by the engineer.

Where the material in the subgrade (that is within 500 mm from the lowest level of the
pavement) has a density less than specified in Table 300-2, the same shall be loosened to
a depth of 500 mm and compacted in layers in accordance with the requirements of
clause 305. 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 300.1.3.11. After
satisfying the density requirements, the cut formation shall be prepared to receive the
subbase/base course in accordance with clause 300.10 and 300.11 to receive the sub-
base/base course.

300.1.7 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.

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 The finished cut formation shall satisfy the surface tolerances described in clause
900.2. Where directed, the topsoil removed earlier and conserved (clauses 300.1.3.2 and
300.5.3.3) 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.

300.1.8 Measurements for payment - Excavation for roadway shall be measured by

taking cross-sections at suitable intervals in the original position before the work starts and
after 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 indicator during excavations
of such shape and size and in such 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-
section 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:

(i) Loosening and recompacting the

loosened material at subgrade……………………….….. cu. m.

(ii) Loosening and removal of unsuitable

material and replacing with a suitable
material and compacting to
required density…………………………………………….. cu. m.

(iii) Preparing rocky subgrade ……………………………..sq. m.

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(iv) Stripping including storing and
reapplication of topsoil………………………………..cu. m.

(v) Disposal of surplus material beyond ………………..cu. m.

initial 1000 m lead

300.1.9 Rates
300.1.9.1 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) setting 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 300.11 ; and

(vi) all labour, materials, tools, equipment, safety measures, testing and incidentals
necessary to complete the work to specifications.

Provided, however, where presplitting is prescribed to achieve a specified slope in rock

excavation, the same shall be paid for vide clause 300.3.5.

300.1.9.2 The contract unit rate for loosening and recompacting the loosened materials at
subgrade shall include full compensation for loosening to the specified depth, including
breaking clods, spreading in layers, watering where necessary and compacting to the
requirements.

300.1.9.2 clauses 300.1.9.1 and 300.5.8 shall apply as regards contract unit rate for item
of removal of unsuitable material and replacement with suitable material respectively.

300.1.9.3 The contract unit rate for item of preparing rocky subgrade as per clause
300.1.6 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.

300.1.9.4 The contract unit rate for the items of stripping and storing topsoil and of
reapplication of topsoil shall include full compensation for all the necessary operations
including all lifts, but leads upto 1000 m.

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300.1.9.5 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.

300.4 Specification for excavation for structures

300.4.1 Scope - Excavation for structures shall consist of the removal of material for the
construction of foundations for bridges, culverts, retaining walls, headwalls, cutoff walls,
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 and foundations; trimming bottoms of excavations; backfilling and
clearing up the site and the disposal of all surplus material.

300.4.2 Classification of excavation - All materials involved in excavation shall be

classified in accordance with clause 300.1.2.

300.4.3 Construction operations

300.4.3.1. Setting out - After the site has been cleared according to clause 200.1, all
limits of excavation shall be set out true to lines, curves and slopes to clause 300.1.3.1.
300.4.3.2. 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 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 300.2 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.

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300.4.3.3.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 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 out 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 before hand 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 the drained water as not
to cause damage to the works, crops or any other property.

300.4.3.4 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 2100.4.1 Ordinary filling shall not be used for the
purpose to bring the foundation to level.

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When rock or other hard strata is encountered, it shall be freed of all soft and loose
material, cleaned and to 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 the excavation in rock, annular space around
footing shall be filled with lean concrete (1:3:6 nominal mix) upto the top level of rock.

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.

300.4.3.5. Slips and slip-outs - If there are any slips or slip-outs in the excavation, these
shall be removed by the contractor at his own cost.

300.4.3.6 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, copy enclosed
vide Annexure 300-A.1

300.4.3.7 Backfilling - Backfilling shall be done with approved material after concrete or
masonry is fully set and carried out in such a way as not to cause undue thrust on any part
of the structure. All space between foundation masonry or concrete and the sides of
excavation shall be refilled to the original surface in layers not exceeding 150 mm
compacted thickness. The compaction shall be done with the help of suitable equipment
such as mechanical tamper, rammer, plate vibrator etc., after necessary watering, so as to
achieve a density not less than the field density before excavation.
300.4.3.8 Disposal of surplus excavated materials - Clause 300.1.3.11., shall supply.

300.4.4. Measurements for payment - Excavation for structure shall be measured in cu.
m., for each class of material encountered, limited to the dimensions shown on the
drawings or as directed by the engineer. Excavation over increased width, cutting of
slopes, shoring, shuttering and planking shall be deemed as convenience for the
contractor in executing the work and shall not be measured and paid for separately,
unless specifically provided for in the contract documents.

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 latter case, payment shall be on
lumpsum basis as provided in the bill of quantities.

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300.4.5 Rates
300.4.5.1 The contract unit rate for the items of excavations 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 contract;

(v) backfilling, clearing up the site and disposal of all surplus material within all lifts and
leads upto 1000 m or as otherwise specified; and

(vi) all labour, materials, tools, equipment, safety measures, diversion of traffic and
incidentals necessary to complete the work to specifications.

300.4.5.2. 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.

300.4.5.3 The contract unit rate for transporting materials from the excavation for
structures 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.
300.5 SPECIFICATIONS FOR EMBANKMENT CONSTRUCTION
300.5.1 General description - These Specifications shall apply to the construction of
embankments including subgrades, earthern shoulders and 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 constructed in accordance with the requirements of these Specifications and in
conformity with lines, grades, and cross-sections shown on the drawings or as directed by
the engineer.

300.5 Materials and general requirements

300.5.2.1 Physical requirements
300.5.2.1.1 The materials used in embankments, subgrades, earthen shoulders and
miscellaneous backfills shall be soil, moorum, gravel, a mixture of these or any other

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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:

1.Materials from swamps, marshes and bogs;

2.Peat, log, stump and perishable matertial; any soil that classifies at OL, OI, OH or Pt in
accordance with IS; 1498 , copy enclosed vide Annexure 300-A.2.

3. Materials susceptible to spontaneous combusion;

4. Materials in a frozen condition;

5.Clay having liquid limit exceeding 70 and plasticity index exceeding 45; and

6.Materials with salts resulting in leaching in the embankment.

300.5.2.1.2 Expansive clay exhibiting marked swell and shrinkage properties (“free
swelling index” exceeding 50 per cent when tested as per IS : 2720-Part 40 shall not be
used as a fill material, subgrade and top 500 mm portion of the embankment just below
subgrade shall be non-expansive in nature.

300.5.2.1.3 Any fill material with a soluble sulphate content 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 9 shall not be deposited within 500
mm, or other distances described in the contract, of metallic items forming part of the
permanent works.

300.5.2.1.4 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.

300.5.2.1.5 Ordinarily, only the materials satisfying the density requirements given in
Table 300-1 shall be employed for the construction of the embankment and subgrade.

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 Table 300-1 Density requirements of embankment and subgrade materials
Sl.No Type of work Maximum laboratory dry unit
. weight when tested as per
IS:2720 (part 8)
1 Embankments up to 3 metres Height, not Not less than 15.2. K N/Cu.m
subjected to extensive Flooding.
2 Embankments exceeding 3 metres Height or Not less than 16.0 kN/cu.m.
embankments of any height Subject to long
periods of inundation
3 Subgrade and earthen shoulders/ Verges/backfill Not less than 17.5.kN/cu.m.

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 300-2.

300.5.2.2 General requirements - The materials for embankment shall be obtained from
approved sources with preference given to materials becoming available from nearby
roadway excavation or any other excavation under the same contract.

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.

300.5.2.2.2. 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 sole responsibility of the contractor.

Haulage of material to embankments or other areas of fill shall proceed only when
sufficient spreading and compaction plant is operating at the place of deposition.

No excavated acceptable material other than surplus to requirements of the contract shall
be removed from the site. Should the contractor be permitted to remove acceptable
material from the site to suit his operational procedure, then he shall make good any
consequent deficit of material arising therefrom.

Where the excavation reveals a combination of acceptable and unacceptable materials,

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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 design dimension so that
surplus material may be trimmed, ensuring that the remaining material is to be density and
in position specified and conforms to the specified side slopes.

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.

300.5.2.2.4 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 300.5.4.6. shall apply.

300.5.2.2.4 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.

300.5.2.2.5. 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
percent 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

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compacted in layers in accordance with clauses 300.5.3.5 and 300.5.3.6 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 in the embankment
foundation shall be removed and replaced by approved materials laid in layers to the
required degree of compaction.

Table 300-2 Compaction requirements for embankment and subgrade

Relative compaction as percentage of
Sl.No Type of work / material max. laboratory dry density as per IS :
2720 (Part 8)
1 Subgrade and earthen shoulders Not less than 97
2 Embankment Not less than 95

3 Expansive Clays
(a) Subgrade and 500 mm Not allowed

portion just below the

subgrade Not less than 90
(b) Remaining portion of

embankment

The contractor shall at least 7 working days before commencement of compaction submit
the following to the engineer for approval:

1) 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 fill materials he intends to use.

2) A graph of density plotted against moisture content from, which each of the values in
(1) above of maximum dry density and optimum moisture content were determined.

3) 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.

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300.5.3 Construction operations
300.5.3.1. Setting out: After the site has been cleared to clause 200.1, the work shall be
set out to clause 300.1.3.1. 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 design dimension so
that surplus material may be trimmed ensuring that the desired material is to the required
density and in position specified and confirms to the specified side slopes.
Embankment or subgrade work shall not proceed until the foundations for
embankment/subgrade have been inspected by the engineer for satisfactory
condition and approved.

300.5.3.4.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) clause
300.5.2.1, at least 500 mm of such material must be removed and replaced by acceptable
fill material before embankment construction commences.
300.5.3.5. Spreading material in layers and bringing to appropriate moisture
content.
300.5.3.5.1 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 placed 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.

300.5.3.5.2 Moisture content of the material shall be checked at the site of placement prior
to commencement of compaction; if found to be out of aged 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 a variable widths of surface but without any flooding. The
water shall be added uniformly 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.

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
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(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 grader,
harrows, rotary mixers or as otherwise approved by the engineer until the layer is
uniformly wet.

Clods or hard lumps or 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.

300.5.3.5.3. 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 constructed with steeper
side slopes, or to greater widths than those shown in the contract, except to permit
adequate compaction at the edges before trimming back, or to obtain the final profile
following any settlement of the fill and the underlying material.

Whenever fill is to be deposited against the face of a natural slope, or sloping earthworks
face including embankments, cuttings, other fills and excavations steeper than 1 vertical
on 4 horizontal, such faces shall be benched as per clause 300.5.4.1 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.

300.5.3.6. 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 be 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 compaction.

The contractor shall demonstrate the efficacy of the equipment he intends to use by

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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 900.3.2.2 and accepted by the engineer. The engineer may
permit measurement of field dry density by a 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)-copy enclosed as
Annexure 300-A.7. A record of the same shall be maintained by the contractor.

When density measurements reveal any soft areas in the embankment /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.

3005.5.3.7. Drainage - The surface of the embankment/subgrade at all times during

construction shall be maintained at such a cross fall (not flatter than that required for
effective drainage of an earthen surface) as will shed water and prevent ponding.

300.5.3.8 Repairing of damages caused by rain/spillage of water - The soil in the

affected portion shall be removed in such areas as 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 300.5.3.6. 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.

300.5.3.9. Finishing operations - Finishing operations shall include the work of shading
and dressing the shoulders/verge/roadbed and side slopes to conform to the alignment,
levels, cross-sections and dimensions shown on the drawings or as directed by the
engineer subject to the surface tolerance described in clause 900.2. 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.

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The topsoil, removed and conserved earlier (clause 300.1.3.2 and 300.5.3.3) 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 mm to 150 mm.

Where directed, the slopes shall be turfed with sods in accordance with clause 300.7. If
seeding and mulching of slopes is prescribed, this shall be done to the requirement of
clause 300.8.

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.

300.5.4 ADDITIONAL SPECIFICATIONS CONSTRUCTION OF EMBANKMENT AND

SUBGRADE UNDER SPECIAL CONDITIONS
300.5.4.1. 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 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 with the help of small vibratory rollers/plane
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.

300.5.2.2 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 300.5.4.1., 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 poijt
shall be provided as per the drawings, before the fill is placed against sloping ground.

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Where the contract requires construction of transverse subsurface drain at the cut – fill
interface, work on the same shall be carried out to clause 300.9 in proper sequence with
the embankment and subgrade work as approved by the engineer.

300.5.4.3 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:-

1) 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.

2) 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.

3) If the level difference between the existing road surface and the new formation level is
more than 1 m, the existing surface shall be permitted to stay in place without any
modification.

300.5.4.4 Embankment and subgrade around structures - To avoid interference with

the construction of abutments, wing walls or return walls of culvert/bridge structures, the
contractor shall, at points to be determined by the engineer suspend work on embankment
forming approaches to such structures, until such time as the construction of the latter is
sufficiently advanced to permit the completion of approaches without the risk of damage to
the structure.

Unless directed otherwise, the filling around culverts, bridges and other structures upto a
distance of twice the height of the road from the back of the abutment shall be carried out
independent of the work on the main embankment. The fill material shall not be placed
against any abutment or wing wall, unless permission has been given by the engineer but
in any case not until the concrete or masonry has been in position for 14 days. The
embankment and subgrade shall be brought up simultaneously in equal layers on each
side of the structure to avoid displacement and unequal pressure. The sequence of work
in this regard shall be got approved from the engineer.

The material used 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 IS: 2720
(Part 5) - Filling behind abutments and wing walls for all structures shall conform to the
general guidelines given in Appendix 6 of IRC: 78 (Standard Specifications and Code of
Practice of 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.

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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 2500.2/300.9.3.2.,
(B) unless otherwise specified in the contract.

Where it may be impracticable to use conventional rollers, the compaction 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.

300.5.4.5 ADDITIONAL SPECIFICATIONS CONSTRUCTION OF EMBANKMENT OVER

GROUND INCAPABLE OF SUPPORTING CONSTRUCTION EQUIPMENT - Where
embankment is to 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
300.5.3.

300.5.4.6 ADDITIONAL SPECIFICATIONS FOREMBANKMENT 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.

300.5.4.7 ADDITIONAL SPECIFICATIONS 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 of high embankment for approval of the engineer, who reserves the right to accept
or reject it.

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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 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.

300.5.4.8 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.

300.5.5 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.

300.5.6 Surface finish and quality control of work - The surface finish of construction of
subgrade shall conform to the requirements of clause 900.2. Control on the quality of
materials and works shall be exercised in accordance with clause 900.3.

300.5.7 Subgrade strength

300.5.7.1 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.

300.5.7.2 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 from the compacted subgrade
in CBR mould fitted with cutting shoe or on remoulded samples, compacted to the field
density at the fixed moisture content.

300.5.8 Measurements for payment - Earth embankment/subgrade construction shall be

measured separately by taking cross sections at intervals in the original position before
the work starts and after its completion and computing the volumes of earthwork in cubic
metres by the method of average end areas. The measurements of fill material from
borrow areas shall be the difference between the net quantities of compacted fill and the
net quantities of suitable material sought from roadway and drainage excavation. For this
purpose, it shall be assumed that one cu. m. of suitable material brought to site from road

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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 measured 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 measured in square metres.

Dismantling and removal of existing cement concrete pavement shall be measured vide
clause 200.2.6.

Filter medium and backfill material behind abutments, wing walls and other retaining
structures shall be measured as finished work in position in cu. m.

300.5.9 Rates
300.5.9.1 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 :
1) Cost of arrangement of land as a source of supply of material of required quantity for
construction unless provided otherwise in the contract ;

2) Setting out ;
1) Compacting ground supporting embankment/subgrade except where removal and
replacement of unsuitable material or loosening and recompacting is involved;

2) Scarifying or cutting continuous horizontal benches 300 mm wide on side slopes of

existing embankment and subgrade as applicable ;

5) Cost of watering or drying of material in borrow areas and/or embankment and

subgrade
during construction as required;
6) Spreading in layers, bringing to appropriate moisture content and compacting to
Specifications requirements ;

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7) Shaping and dressing top and slopes of the embankment and subgrade including
rounding of corners;

8) Restricted working at sites of structure ;

9) Working on narrow width of embankment and subgrade;

10) 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;
11) All labour, materials, tools, equipment and incidentals necessary to complete the work
to the Specifications;

12) Dewatering; and

13) Keeping the embankment/ completed formation free of water as per clause 300.11.

300.5.9.2. 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
transportation involved beyond the specified initial lead.

300.5.9.3. Clause 300.1.9.5 shall apply as regards contract unit rates for items of
stripping and storing topsoil and of reapplication of topsoil.

300.5.9.4., clause 300.1.9.2., shall apply as regards contract unit rate for the item of
loosening and recompacting the embankment/subgrade foundation.

300.5.9.5.clauses 300.1.9.1., and 300.5.8 shall apply as regards contract rates for items of
removal of unsuitable material and replacement with suitable material respectively.
300.5.9.6. The contract unit rate for scarifying existing granular/bituminous 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 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.

300.5.9.7. Clause 200.2.7 shall apply as regards contract unit rate for dismantling and
removal of existing cement concrete pavement.

300.5.9.8. The contract unit rate for providing and laying filter material behind abutments
shall be payment in full for carrying out the required operations including all materials,

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labour, tools, equipment and incidentals to complete the work to specifications.

300.5.9.9. Clause 300.5.4.6 shall apply as regards contract unit rate for construction of
embankment under water.

300.5.9.10 Clause 300.5.4.7 shall apply as regards contract unit rate for construction of
high embankment. It shall include cost of instrumentation, its monitoring and settlement
period, where specified in the contract or directed by the engineer.

SECTION 400
GRANULAR SUB-BASE, BASES(NON-BITUMINOUS) AND SHOULDERS

400.1 SPECIFICATIONS FOR GRANULAR SUB–BASE, BASES(NON-BITUMINOUS)

AND SHOULDERS
400.1.1 Scope - This work shall consist of laying and compacting well-graded material on
prepared subgrade in accordance with the requirements of these specifications. The
material shall be laid 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.

400.1.2 Materials
400.1.2.1 The material to be used for the work shall be natural sand, moorum, gravel,
crushed stone, or combination thereof depending upon the grading required. Materials like
crushed slag, crushed concrete, brick metal and kankar may be allowed only with the
specific approval of the engineer. The material shall be free from organic or other
deleterious constituents and conform to one of the three gradings given in Table 400-1.

While the gradings in Table 400-1 are in respect of close-graded granular sub-base
materials, one each for maximum particle size of 75 mm, 53 mm and 26.5 mm, the
corresponding gradings for the coarse-graded materials for each of the three maximum
particle sizes are given at Table 400-2. The grading to be adopted for a project shall be as
specified in the contract.

400.1.2.2 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 BIS:812 (Part
III). The water absorption value of the coarse aggregate shall be determined as per IS :
2386 (Part 3) if this value is greater than 2 per cent, the soundness test shall be carried
out on the material delivered to site as per IS : 383 For Grading II and III materials, the
CBR shall be determined at the density and moisture content likely to be developed at the
density and moisture content likely to be developed in equilibrium conditions which shall
be taken as being the density relating to a uniform air voids content of 5 per cent.

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 Table 400-1 Grading for close graded granular sub-base materials

IS sieve Percent by weight passing the IS sieve

Designation Grading I Grading II Grading III
75.0 mm 100 - -
53.0 mm 80-100 100 -
26.5 mm 55-90 70-100 100
9.50 mm 35-65 50-80 65-95
4.75 mm 25-55 40-65 50-80
2.36 mm 20-40 30-50 40-65
0.425 mm 10-25 15-25 20-35
0.075 mm 3-10 3-10 3-10
CBR value (Minimum 30 25 20

Table 40-0-2 Grading for coarse graded granular sub-base materials

IS sieve Percent by weight passing the IS sieve
Designation Grading I Grading II Grading III
75.0 mm 100 - -
53.0 mm 100
26.5 mm 55-75 50-80 100
9.50 mm
4.75 mm 10-30 15-35 25-45
2.36 mm
0.425 mm
0.075 mm <10 <10 <10
CBR value (minimum) 30 25 20

Note: The material passing 425 micron (0,425 mm) sieve for all the three gradings when
tested according to IS : 2720 (Part 5) shall have liquid limit and plasticity index not more
than 25 and 6 per cent respectively.

400.1.3 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 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.

400.1.4 Construction operations

400.1.4.1 Preparation of subgrade - Immediately prior to the laying of sub-base, the

subgrade already finished to clause 300.1 to 300.5 as applicable shall be prepared by

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removing all vegetation and other extraneous matter, lightly sprinkled with water if
necessary and rolled with two passes of 80 – 100 KN smooth wheeled roller.
400.1.4.2 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 mortar 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 mentioned in clause

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

Moisture content of the loose material shall be checked in accordance with IS : 2720 (Part
2) and suitably adjusted by sprinkling additional water from a truck mounted or trailer
mounted water tank and suitable for applying water uniformly and at controlled quantities
to variable widths of 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 compacted layer does not
exceed 100 mm, a smooth wheeled roller of 80 to 100 KN weight may be used. For a
compacted single layer upto 225mm the compaction shall be done with the help of a
vibratory roller of minimum 80 to 100 KN static weight with plain drum or pad foot-drum or
heavy pneumatic tyred roller of minimum 200 to 300 KN weight having a minimum tyre
pressure of 0.7 MN/m2 or equivalent capacity roller capable of achieving the required
compaction. Rolling shall commence at the lower edge and proceed towards the upper
edge longitudinally for portions having unidirectional crossfall and super-elevation and
shall commence at the edges and progress towards the centre for portions having
crossfall on both sides.
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 becomes apparent, corrected by removing or adding fresh material.
The speed of the roller shall not exceed 5 km per hour. Rolling shall be continued till the density
achieved is at least 98 per cent of the maximum dry 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.

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400.1.5 Surface finish and quality control of work - The surface finish of construction
shall conform to the requirements of clause 900.2. Control on the quality of materials and
works shall be exercised by the engineer in accordance with section 900.

400.1.6. Arrangements for traffic - During the period of construction, arrangement of

traffic shall be maintained in accordance with clause 100.12.

400.1.7. Measurement for payment - 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.

400.1.8. Rate - The contract unit rate for granular sub-base shall be payment in for
carrying out the required operations including full compensation for:
(i) making arrangements for traffic according to clause 100.12 except for initial treatment
to verges, shoulders and construction of diversions;
(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 specifications;
(iv) carrying out the work in part widths of road where directed; and
(v) carrying out the required tests for quality control.

400.4 SPECIFICATIONS FOR WATER BOUND MACADAM SUB – BASE / BASE

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

400.4.1.2 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.

400.4.2 Materials
400.4.2.1.Coarse aggregates - Coarse aggregates shall be either crushed or broken
stone, crushed slag, overburnt (Jhama) brick aggregates or any other naturally occurring
aggregates such as kankar and laterite of suitable quality. Materials other than crushed or
broken stone and crushed slag shall be used in sub-base courses only. If crushed gravel/
shingle is used, not less than 90 per cent by weight of the gravel/shingle pieces retained
on 4.75 mm sieve shall have at least two fractured faces. The aggregates shall conform to

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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)- copy
enclosed as Annexure.

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

Table 400-6, Physical requirements of coarse aggregates for water bound macadam for
sub– base courses
Test Test Method Requirements
1 * Los Angeles Abrasion IS:2386 40 percent (Maxi.)
value
Or IS:2386 (Part-4) or 30 percent (Maxi.)
*Aggregate impact value IS;5640**
2 Combined Flakiness and IS:2386 (Part - 1) 30 percent (Maxi.)
Elongation indices (Total)***
* Aggregate may satisfy requirements of either of the two sets.
** Aggregates like brick metal, kankar, laterite etc. which get softened in presence of
water shall be tested for Impact value under wet condition 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.

400.4.2.3. 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 material
shall not be more than 20. It should also comply with the following requirements:

(i) Chemical stability To comply with requirements of appendix of

BS : 1047
(ii) Sulphur content Maximum 2 per cent
(iii) Water absorption Maximum 10 per cent
400.4.2.4. Overburnt brick aggregates - Brick aggregates shall be made from overburnt
bricks or brick bats and be free from dust and other objectionable and deleterious
materials.

400.4.2.5. Grading requirement of coarse aggregates - The coarse aggregates shall

conform to one of the Gradings given in Table 400 – 7 as specified, provided, however,
the use of Grading No. 1 shall be restricted to sub-base courses only.

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 Table 400 – 7, Grading requirements of coarse aggregates
Gradation Size range I.S. Sieve designation Percent by weight passing
1 90 mm to 45 mm 125 mm 100
90 mm 90-100
63 mm 25-60
45 mm 0-15
22.4 mm 0-5
2 63 to 45 mm 90 mm 100
63 mm 90-100
53 mm 25-75
45 mm 0-15
22.4 mm 0-5
3 53 to 22.4 mm 63 mm 100
53 mm 95-100
45 mm 65-90
22.4 mm 0-10
11.2 mm 0-5

Note: The compacted thickness for a layer with Grading 1 shall be 100 mm while for
layer with other gradings i.e., 2 & 3, it shall be 75 mm.

400.4.2.6. Screenings - Screenings to fill voids in the coarse aggregate shall generally
consist of the came 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.

Screenings shall conform to the grading set forth in Table 400-8. The consolidated details
of quantity of screenings required for various grades of stone aggregates are given in
Table 400 – 9. The table also gives the quantities of materials (loose) required for 10 m2
for sub-base base compacted thickness of 100/75 mm. The use of screenings shall be
omitted in the case of soft aggregates such as brick metal, kankar, laterites, etc. as they
are likely to get crushed to a certain extent under rollers.

Table 400 – 8, Grading for screenings

Grading Size of IS Sieve Per cent by weight
classification screenings designation passing the IS sieve
A 13.2 mm 13.2 mm 100
11.2 mm 95-100
5.6 mm 15-35
180 mcn 0-10
B 11.2 mm 11.2 mm 100
5.6 mm 90-100
180 mcn 15-35
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 Table 400 – 9, Approximate quantities of coarse aggregates and screenings required for
100 / 75 mm compacted thickness of water bound macadam (wbm) sub-base /
base course for 10 m2 area
Screenings
Crushable type such as
Stone screening
mooram or gravel
Classific Size Compact Loose
Grading For WBM Grading
ation Range thickness Qty.
classification sub-base/ classification
Loose Qty.
and size base course and size
(loose Qty)
Grading1 90 mm 100 mm 1.21 to Type A 13.2 0.27 to 0.30 Not Uniform 0.30 to 0.32
to 45 1.43 m3 mm m3 m3
mm
Grading2 63mm 75 mm 0.91 to Type A 13.2 0.12 to 0.15 - do - 0.22 to 0.24
to 45 1.07m3 mm m3 m3
mm
- do - - do - - do - - do - Type B 11.2 0.20 to 0.22 - do - - do -
mm m3
Grading3 53mm 75 mm - do - - do - 0.18 to 0.21 - do - - do -
to 22.4 m3
mm

400. 4.2.7. Binding material - Binding material to be used for water bound macadam as a
filter 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 – 0.10 m3/ 10 m2 for 100 mm
compacted thickness.

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.
400.4 Construction operations
400.4.3.1 Preparation of base - The surface of the subgrade /sub-base/base to the
specified lines and crossfall (camber) and made free of dust and other extraneous
material. Any ruts or soft yielding places shall be corrected in an approved manner and
rolled until firm surface is obtained if necessary by sprinkling water. Any sub-base /base /
surface irregularities, where predominant, shall be made good by providing appropriate
type of profile corrective course (levelling course) to clause 500.1 of these specifications.

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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.

400.4 3.2 Inverted choke - If water bound macadam is to be laid directly over the
subgrade, without any other intervening pavement course, a 25 mm course of screenings
(Grading B) or coarse sand shall be spread on the prepared subgrade before application
of the aggregates is taken up. In case of a fine sand or silty or 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 to act as a drainage layer as
well. As a preferred alternative to inverted choke, appropriate geosynthetics performing
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.

400.4.3.3 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 400.4.2.5. Wherever possible, approved
mechanical devices such as aggregates spreader shall be used to spread the aggregates
uniformly so as to minimise the need for manual rectification afterwards. Aggregates
placed at spread in one or more layers by any approved means so as to achieve the
specified results.

The spreading shall be done from stockpiles along the side of the roadway or directly from
vehicles. No segregation of large or fine aggregates shall be allowed and the coarse
aggregate as spread shall be of uniform gradation with no pockets of fine material.
The surface of the aggregates spread shall be carefully checked with templates and all
high or low spots remedied by removing or adding aggregates as may be required. The
surface shall be checked frequently with a straight edge while spreading and rolling so as
to ensure a finished surface as per approved drawings.

The coarse aggregates shall not normally be spread more than 3 days in advance of the
subsequent construction operations.

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400.4.3.4 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.

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 compacted with sufficient
void space in them to permit application of screenings. However, where screenings are
not to be applied, as in the case of crushed aggregates like brick metal, laterite and
kankar, compaction shall be continued until the aggregates are thoroughly keyed. During
rolling, slight sprinkling of water may be done, if necessary. Rolling shall not be done
when the subgrade is soft or yielding or when it causes a wave-like motion in the
subgrade or sub-base course.

The 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 crossfall
(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 400.7.4.1.

400.4.3.5 Application of screenings - After the coarse aggregate has been rolled to
clause 400.4.3.4, 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 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 aggregates.
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 arrangement. 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 accompanied by dry rolling and becoming
with mechanical brooms, hand-brooms or both. In no case shall the screenings be applied
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so fast and thick as to form cakes or ridges on the surface in such a manner as would
prevent filling of voids or prevent the direct bearing of the roller on the coarse aggregate.
These operations shall continue until no more screenings can be forced into the voids of
the coarse aggregate.

The spreading, rolling, and brooming of screenings shall be carried out in only such
lengths of the road which could be completed within one day’s operation.

400.4.3.6 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.

400.4.3.7 Application of binding material - After the application of screenings in

accordance with clauses 400.4.3.5 and 400.4.3.6.. the binding material where it is
required to be used (clause 400.4.2.7.) 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.

400.4.3.8 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 material as directed, lightly sprinkled with water if
necessary and rolled. No traffic shall be allowed on the road until the macadam has set.
The engineer shall have the discretion to stop hauling traffic from using the completed
water bound macadam course, if in his opinion it would cause excessive damage to the
surface.

The compacted water bound macadam course should be allowed to completely dry and
set before the next pavement course is laid over it.

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400.4.4.Surface finish and quality control work
400.4.4.1.The surface finish of construction shall conform to the requirements of clause
900.2.

400.4.4.2. Control on the quality of materials and works shall be exercised by the engineer
in accordance with section 900.

400.4.4.3. The water bound macadam work shall not be carried out when the atmospheric
temperature is less than 0 deg. C. in the shade.

400.4.4.4. Reconstruction of defective macadam - The finished surface of water bound

macadam shall conform to the tolerance of surface regularity as prescribed in clause
900.2. However, where the surface irregularity 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.

400.4. Arrangement for traffic - During the period of construction, the arrangement of
traffic shall be done as per clause 100.12.

400.4.6 Measurements for payment - Water bound macadam shall be measured as

finished work in position in cubic metres.

400.4.7 Rate - The contract unit rate for water bound macadam sub-base/base course
shall be payable in full compensation for all components listed in clause 400.1.8 (I) to (v)
including arrangement of water used in the work as approved by the engineer

SECTION 500

GERNERAL REQUIREMENTS FOR BITUMINOUS PAVEMENT LAYERS

(UPGRADED VERSION(U.V) – NOVEMBER 2000)

500.1.1 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 contrast specification for that project.

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500.1.2 Materials
500.1.2.1 Binder - The binder shall be an appropriate type of bituminous materials
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 bitumen in the penetration range 30 to 40. Where
Modified Binder is specified, the clause 500.2.1 of these specifications shall apply.

500.1.2.2 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.

500.1.2.3 Fine aggregates

Fine aggregates shall consist of crushed or naturally occurring material, or a combination
of the two, passing 2.36 mm sieve and retained on 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.

500.1.2.4 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 from time to time withdraws
approval of a specific source, or attaches conditions to the existing approval. Any change
in aggregate source for bituminous mixes will require a new mix design, and laying trials,
where the mix is based on a job mix design. Stockpiles from different sources, approved
or otherwise, shall be kept separate, such that there is no contamination between one
material and another. Each source submitted for approval shall contain sufficient material
for at least 5 days work.

500.1.3 Mixing
Pre-mixed bituminous materials. Including bituminous macadam, dense 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
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can be found in Table 500-5 of these specifications; the difference in temperature between
the binder and aggregates should at not exceed 140C. 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 continuos 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.

500.1.4 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 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.

500.1.5 Laying
500.1.5.1 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 0C or when the wind speed
at any temperature exceeds 40 km/h at 2m height unless specifically approved by the
engineer.
500.1.5.2 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 shall be available full time on the site, unless
otherwise specified in the contract.
500.1.5.3 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 paver cannot be used, the material shall be spread, raked and
leveled with suitable hand tools by experienced staff, and compacted to the satisfaction of
the engineer.

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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 expansion joint of a structure, machine laying shall
stop 300 mm short of the joint. The remainder of the pavement up to joint, 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 1450C, shall not be laid or deposited
on bridge deck waterproofing systems, unless precautions against heat damage have
been approved by engineer.

Hand placing of pre-mixing 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 500.15.
(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.
500.1.5.2 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 500.1.8.

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.

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500.1.6 Compaction - Bituminous materials shall be laid and compacted in layers which
enable the specified thickness, surface level, regularity requirement 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 onwards 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 the 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 pneumatic tyred roller, at least the
nominal width of 300 mm.

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.

Rollers should move at a speed of not more than 5 km per hour. 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

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good working order, to prevent the mixture from adhering other 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.
500.1.7 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 heater 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 than 75 mm. The
contractor shall have equipment available, for use in the event of a heater breakdown, to
form joints by methods (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) by cutting back the exposed joint, for a distance equal to the specified layers
thickness,
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 is appropriate. Longitudinal
joints shall not be situated in wheel track zones.

500.1.8 Preparation of surface

500.1.8.1 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 engineer. The existing surface shall
be firm and clean, and treated with prime or tack coat as shown on the drawings as
otherwise stated in the contract.

200.1.8.2 Materials
500.1.8.2.1 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 400.4: Water Bound Macadam or
clause 406:Wet Mix Macadam of the Ministry’s Specification for Road and Bridge Works
(third revision) 1995.

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500.1.8.2.2 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 3000.4.2 and 3000.4.3, or as directed by the engineer.

500.1.8.2.3 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.

500.1.8.2.4 Profile corrective course and its application - The type of material for use
as profile corrective shall be as shown on the drawings or as directed by the engineer.
While it is to be laid as part of the overlays/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 part 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.

500.1.8.3 Construction operations

500.1.8.3.1 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 500.2.

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.

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After cleaning the surface shall be correct to line and level, within the tolerances specified
for base course.

500.1.8.3.2 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 that 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 500.2. Reusable materials shall be stacked as directed by the engineer within
1000 m of their origin.

500.8.3.3 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 3000.4.2 and 3000.4.3, or as directed the engineer.

500.1.8.3.4 Laying the profile corrective course

500.8.3.4.1 Laying on granular base - After preparing the granular surface in accordance
with clauses 500.1.8.3.1 and 500.1.8.3.2, the profile corrective course shall be laid using
material as described in Cluses500.1.8.2.3 and 500.1.8.3.2.4, or otherwise described in
the contract, and compacted to the requirements of the particular specifications.

500.1.8.3.4.2 Laying on existing bituminous surface - The existing bituminous surface

shall be prepared in accordance with clause 500.1.8.3.3, and after applying a tack coat
conforming to clause 500.3, the bituminous profile corrective course shall be laid and
compacted to the requirements of the particular specification.
500.1.8.3.4.3 Correction of local depression - 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

showed in Figure. 500-2 shall be adopted, depending on the profile of the existing
carriageway.

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 (A) Correct method

(A) Incorrect method

Fig 500-1 Method for providing corrective course for short sags and depressions
Note: Profile corrective course material to be in accordance with the lift thickness

500.1.8.3.5 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.

500.1.8.4 Surface finish and quality control of work - The relevant provisions of section
900 shall apply.

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Fig 500-2 Correction of the camber of superelevision

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500.1.8.5 Arrangements for traffic - During construction operations, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12.

500.1.8.6 Environmental protection - The provisions of clause 100.11 of the Ministry’s

Specification for Road and Bridge Works (third revision) 1995 and the provision of
Annexure A to clause 500.1 shall apply.

500.1.8.7 Measurement for payment

500.1.8.7.1 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.

The work in filling cracks larger than 3 mm in width shall be measured and paid for on a
linear metre basis.

500.1.8.7.2 Scarifying -Scarifying the existing bituminous surface shall be measured on a

square metre basis.

500.1.8.7.3 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.

500.1.8.7.4 Prime coat - Prime coat is to be measured and paid for on a per square metre
basis.

500.8.7.5 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 for, if used, on a
square metre basis.

500.1.8.8 Rates
500.1.8.8.1 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.

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500.1.8.8.2 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 100.12 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
stockyards, all royalties, fees, and rents where necessary and all leads and lifts;
(iv) Mixing, transporting, laying and compacting the mix, as specified.

(v) All labour, tools, equipment, plant including installation of hot mix plant, power supply
units 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 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 materials 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.

500.1.8.8.3 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
500.16.9.

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The contract unit rate for crack sealing 3 mm to 6 mm 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 15 mm is to be measured on a linear
metre basis, and the rate is to include for all materials, tools, plant, labour, and transport.

Annexure ‘A’
SPECIFICATIONS FOR PROTECTION OF THE ENVIRONMENT

1. General
1.1 This section of the specifications 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 abutment 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.

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.
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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 tailboards. 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
tailboards.

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.
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 a 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 noise 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 deposition 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, gravel’s, 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 spillage of oil or bitumen or chemicals.

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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.

500.2 SPECIFICATIONS FOR PRIME COAT OVER GRANULAR BASE (UV - NOV
2000)
500.2.1 Scope - This work shall consist of the application of a single coat of low viscosity
liquid bituminous material to a porous granular surface preparatory to the superimposition
of bituminous treatment or mix.

500.2.2 Materials
500.2.2.1 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.

500.2.2.2 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

Kinematic viscosity of Primer Quantity of Liquid Bituminous
Type of surface at 600C Material per 10 Sq.cm.
(Centistokes) (kg)
Low porosity 30-60 6 to 9
Medium porosity 70-140 9 to 12
High porosity 250-500 12 to 15

500.2.2.3 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 engineer.

500.2.3 Weather and seasonal limitations - Bituminous primer shall not be applied to a
wet surface (see 500.2.4.2) or during a dust storm or when the weather is foggy, rainy or
windy or when the temperature in the shade is less than 100C. Surfaces, which are to
receive emulsion primer, should be damp, but no free or standing water shall be present.

500.2.4 Construction
500.2.4.1 Equipment - The primer distributor shall be a self-propelled or towed bitumen
pressure sprayer equipped for spraying the material uniformly at specified rates and

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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.

500.2.4.2 Preparation of road surface - The surface to be primed shall be prepared in

accordance with clauses 500.1.8 and 900.2 as appropriate. 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.

500.2.4.3 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 (third
revision) 1995 shall apply. The bituminous primer shall be sprayed uniformly in
accordance with clause 500.1. 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.

500.2.4.4 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 the 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 pricking up under the wheels of the paver and the trucks
delivering bituminous materials to the paver.

500.2.4.5 Tack coat - Over the primed surface, a tack coat should be applied in
accordance with clause 500.3

500.2.5 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.

500.2.6 Arrangements for traffic - During construction operations, arrangements for

traffic shall be made in accordance with the provisions of clause 100.12.

500.2.7 Measurement for payment - Prime coat shall be measured in terms of surface
area of application in square metres

500.2.8 Rate - The contract unit rate for prime coat with adjustments as described in
clause 500.2.7 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 500.2.4.3.
500.3 SPECIFICATIONS FOR TACK COAT (UV-NOV 2000)
500.3.1 Scope - This work shall consist of the application of a single coat of low viscosity
liquid bituminous material to an existing bituminous road surface preparatory to the

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superimposition of a bituminous mix, when specified in the contract or instructed by the
engineer.

500.3.2 Materials
500.3.2.1 Binder - The binder used for tack coat shall be bitumen emulsion complying
with IS 8887 of a type and grade as specified in the 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.

500.3.3 Weather and seasonal limitations - Bituminous material shall not be applied to a
wet surface or during a dust storm or when the weather is foggy, rainy or windy or when
the temperature in the shade is less than 100C. Where the tack coat consists of emulsion,
the surface shall be slightly damp, but not wet. Where the tack coat is of cutback bitumen,
the surface shall be dry.

500.3.4 Construction
500.3.4.1 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 directed by the engineer.

500.3.4.2 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 500.1.8 and 900.2 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.

500.3.4.3 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 temperature for a bituminous emulsion shall be 200C to 700C
and for a cutback, 500C to 800C if RC-70/MC-70 is used. Where a geosynthetic is
proposed for use, the provisions of section 700 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.
TABLE 500-2. Rate of application of tack coat
Quantity of liquid bituminous material in
Sl.No. Type of Surface
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
500.3.4.4 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.

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500.3.5 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.
500.3.6 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12.
500.3.7 Measurement for payment - Tack coat shall be measured in terms of surface
area of application in square metres.
500.3.8. 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 400.1.8 (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 per square metre, with the provision that the variance in actual quantity of
bitumen used will be assessed and the payment adjusted accordingly.
500.4 SPECIFICATIONS FOR BITUMINOUS MACADAM (UV-NOV-2000)
500.4.1 Scope - This work shall consist of construction in a single course having 50mm to
100 mm 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 500.7, 500.8 and 500.9.
500.4.2 Materials
500.4.2.1 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.
500.4.2.2 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 Table 500-3.
Table 500-3. Physical requirements for coarse aggregates for bituminous macadam
Property Test specification
1
Grain size analysis Max 5% passing 0.075 mm
Cleanliness
sieve
Flakiness and Elongation Max 30%
Particle shape
Index (Combined)2
Los Angeles Abrasion Value3 Max 40%
Strength*
Aggregate Impact Value3 Max 30%
Soundness:4
Durability Sodium sulphate Max 12%
Magnesium sulphate Max 18%
Water absorption Water absorption5 Max 2%
Coating and Stripping of Minimum retained coating
Stripping Bitumen
Aggregate Mixtures6 95%
Water Sensitivity7 Retained Tensile Strength Min 80%

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Notes:
1. IS:2386 Part 1 4. IS: 2386 Part 5
2. IS: 2386 Part 1 5. IS: 2386 Part 3
(the elongation test to be done only on non-flaky aggregates in the sample)
3. IS: 2386 Part 4* 6. IS: 624c1
7. IS: 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.

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.
500.4.2.3 Fine aggregates - Fine aggregates shall consists of crushed or naturally
occurring material, or a combination of the two, passing 2.36 mm sieve and retained on 75
micron sieve. They shall be clean, hard, durable, dry and free from dust, and soft or
friable matter, organic or other deleterious matter.
500.4.2.4 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.
500.4.2.5 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 provisions
of section 900.

500.4.3 Construction operations

500.4.3.1 Weather and seasonal limitations - The provisions of clause 500.1.5.1 shall
apply.

Table 500-4. Composition of bituminous macadam

Mix designation Grading 1 Grading 2
Nominal aggregate size layer 40 mm 19 mm
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
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.
500.4.3.2 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 500.1.8 and 900.2.3 as appropriate, and a prime coat, shall be applied in
accordance with clause 500.2 where specified, or as directed by the engineer.
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500.4.3.3 Tack coat - A tack coat in accordance with clause 500.3 shall be applied as
required by the contract documents, or directed by the engineer.
500.4.3.4 Preparation and transportation of the mixture - The provisions of clauses
500.1.3 and 500.1.4 shall apply.

500.4.3.5 Spreading - The provisions of clauses 500.1.5.3 shall apply.

Table 500-5. Manufacturing and rolling temperatures

Bitumen Bitumen Aggregate Mixed Rolling Laying
Penetration Mixing (0C) Mixing (0C) Material (0C) (0C) (0C)
35 160-170 160-175 170 Maximum 100 Minimum 130 Minimum
65 150-165 150-170 165 Maximum 90 Minimum 125 Minimum
90 140-160 140-165 155 Maximum 80 Minimum 115 Minimum

500.4.3.6 Rolling - Compaction shall be carried out in accordance with the provisions of
clauses 500.1.6 and 500.1.7.
Rolling shall be continued until the specified density is achieved, or where nod density is
specified, until there is no further movement under the roller. The required frequency of
testing is defined in clause 900.3.

500.4.4 Surface finish and quality control of work - The surface finish of the completed
construction shall conform to the requirements of clause 900.2. for control of the quality of
materials supplied and the works carried out, the relevant provisions of section 900 shall
apply.
500.4.5 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 500.13 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.

500.4.6 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12.

500.4.7 Measurement of payment - 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.

500.4.8. Rate - The contract unit rate of 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 500.1.8.8.2.(i) to (xi).

500.5 SPECIFICATIONS FOR BITUMINOUS PENETRATION MACADAM (UV-

NOV2000)
500.5.1 Scope - The work shall consist of construction of one or more layers of
compacted crushed coarse aggregates with alternate applications of bituminous binder
and key aggregates in accordance with the requirements of these specifications to be
used as a base course on roads, subject to the requirements of the overall pavement
design, in conformity with the lines, grades and cross-sections shown on the drawings or
as directed by the engineer. Thickness of an individual course shall be 50 mm or 75 mm,
or other as specified.

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500.5.2 Materials
500.5.2.1 Bitumen - The binder shall be paving bitumen of suitable penetration grade
within the range of S-35 to S-90 or A-35 to A-90 (30/40 to 80/100) as per Indian Standards
specifications for “Paving Bitumen” IS:73, or approved cutback satisfying the requirements
of IS: 217 or 454. The actual grade of bitumen or cutback to be used shall be as specified
or as directed by the engineer.
500.5.2.2 Aggregates - The aggregates shall satisfy the physical requirements set out in
clause 500.4.2.2 and Table 500-3. The coarse and key aggregates shall conform to the
grading given in Table 500-6.

500.5.2.3 Quantities of materials - The quantities of materials used for this work shall be
as specified in Table 500-6.
500.5.3 Construction operations
500.5.3.1 Weather and seasonal limitations - The provisions of clause 500.1.5.1 shall
apply.
500.5.3.2 Equipment - A mechanical broom, compressor, self propelled or trailed bitumen
heater/distributor, mechanical aggregate spreader and 8 to 10 tonne smooth steel wheel
roller or vibrating roller are required for the preparation of Penetration Macadam.

500.5.3.3 Preparation of the base - The base on which the penetration macadam course
is to be laid shall be prepared, shaped and compacted to the specified lines, grades and
sections to clauses 500.1 and 900.2 as appropriate, or as directed by the engineer. A
prime coat, where specified, shall be applied over the base in accordance with clause
500.2 or as directed by the engineer. A tack coat as per clause 500.3 shall be applied.
500.5.3.4 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

IS Sieve Cumulative per cent by weight of total aggregate passing
Designation (mm) For 50 mm compacted Thickness For 75 mm compacted Thickness
Coarse Key Coarse Key
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 0.6 0.015 0.09 0.018
quantities cu.m/m2
Binder quantity
(penetration 5 6.8
(1) 2
grade) (kg/m )
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Note: (1) If cutback bitumen is used, adjust binder quantity such that the residual bitumen
is equal to the values in this table.

500.5.3.5 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 500.1.6 and 500.1.7 shall apply.

After initial dry rolling, the surface shall be checked with a crown template and a 3 metre
straight-edge. The surface shall not vary more than 10 mm from the template or straight
edge. All surface irregularities exceeding the above 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.

500.5.3.6 Application of bituminous material - After the coarse aggregate has been
rolled and checked, the bituminous binder shall applied, at the rate given in Table 500-6,
in accordance with clause 500.1, 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, not exceeding 10 mm 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.

500.5.3.7 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 Table 500-6.

Where directed by the engineer, the surface shall be swept and the quantity of key
aggregate adjusted to ensure uniform application, with the entire 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 500.5.3.5.

500.5.4 Surface finish and quality control - The surface finish of the completed
construction shall conform to the requirements of clause 900.2. For control of the quality
of materials supplied and the works carried out the relevant provisions of section 900
shall apply.

500.5 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
500.13 before opening to traffic. The seal coat in such cases shall be considered
incidental to the work and shall not be paid for separately.

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500.5.6 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12.
500.5.7 Measurement for payment - Penetration macadam base course shall be
measured as finished work in square metres.

500.5.8 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 500.1.8.8.2.(i) to (xi).

500.6 SPECIFICATIONS FOR BUILT – UP SPRAY GROUT (UV-NOV 2000)

500.6.1 Scope - This work shall consist of a two-layer composite construction of
compacted crushed coarse aggregates with application of bituminous binder after each
layer, and with key aggregates placed on top of the second layer, in accordance with the
requirements of 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.

500.6.2 Materials
500.6.2.1 Bitumen - clause 500.4.2.1 shall apply. Where permitted by the engineer, an
appropriate grade of emulsion with IS 8887 may be used.

500.6.2.2 Aggregates - The coarse aggregate shall conform to clause 500.4.2.2.

The aggregates 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 Designation (mm) Cumulative per cent by weight of total aggregate passing
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

500.6.3 Construction operations

500.6.3.1 Weather and seasonal limitations - The provisions of clause 500.1.5.1 shall
apply.

500.6.3.2 Equipment - The provisions of clause 500.5.3.2 shall apply.

500.6.3.3 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 500.1 and 900.2 as appropriate. A prime coat shall be
applied in accordance with clause 500.2 with approved primer as directed by the engineer.

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500.6.3.4 Tack coat - A tack coat shall be applied in accordance with the procedure
described in clause 500.3, as directed by the engineer.
500.6.3.5 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, 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 super elevated 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.

500.6.3.6 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 15 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.

500.6.3.7 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 500.6.3.5.

500.6.3.8 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 500.6.3.6.

500.6.3.9 Application of key aggregate - Immediately after the second application of

binder, key aggregates shall be spread uniformly and evenly, preferable 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
surface shall then be rolled with an 8-10 tonnes smooth wheel steel roller in accordance
with clause 500.6.3.5. 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.

500.6.4 Surface finish and quality control - The surface finish of construction shall
conform to the requirements of clause 900.2. all materials shall comply with the
requirements of the relevant provisions in section 900 of the specifications.

500.6.5 Final surfacing - The built-up-spray-grout shall be provided with final surfacing
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 500.13 before it is open to traffic.
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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.

500.6.6 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12.

500.6.7 Measurement for payment - Built-up spray grout shall be measured as finished
work in square metres.

500.6.8 Rate - 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 500.1.8.8.2 (i) to (xi).

500.7 SPECIFICATIONS FOR DENSE GRADED BITUMINUS MACADAM (UV– NOV

2000)

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

500.7.2 Materials

500.7.2.1 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 500-10 for dense bitumen macadam, or this bitumen as modified by one
of the methods specified in clause 500.21, or as otherwise specified in the contract.

500.7.2.2 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, and durable, of cubical shape, free from 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
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.

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.

500.7.2.3 Fine aggregates - Fine aggregates shall consist of crushed or naturally

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

The fine aggregate shall have a sand equivalent value of not less than 50 when tested in
accordance with the requirement of IS: 2720 (Part 37).

The plasticity index of the fraction passing the 0.425 mm sieve shall not exceed 4. When
tested in accordance with IS: 2720 (Part 5).
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 Table 500-8. Physical requirements for coarse aggregate for dense graded bituminous
macadam
Property Test specification
1
Cleanliness (dust) Grain size analysis Max 5% passing 0.075 mm
sieve.
Particle shape Flakiness and Elongation Max 30%
Index (combined)2
Strength* Los Angeles Abrasion Value3 Max 35%
Aggregate Impact Value4 Max 27%
Durability Soundness:5
Sodium Sulphate Max 12%
Magnesium Sulphate Max 18%
Water absorption Water absorption6 Max 2%
Stripping Coating and Stripping of Minimum retained coating
Bitumen a Aggregate 95%
7
Mixtures
Water Sensitivity** Retained Tensile Strength8 Min 80%

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

500.7.2.4 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

S 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 percent 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 percent by total weight of aggregate, of hydrated lime shall be added without
additional cost.

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

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 Table 500-10 Composition of dense graded bituminous macadam pavement layers
Grading 1 2
Nominal thickness of
40 mm 25 mm
aggregate
Layer thickness 80-100 mm 50-75 mm
IS Sieve1 Cumulative % by weight of total aggregate passing
45 100 -
37.5 95-100 100
26.5 63-93 90-100
19 - 71-95
13.2 55-75 56-80
9.5 - -
4.75 38-54 38-54
2.36 28-42 28-42
1.18 - -
0.6 - -
0.3 7-21 7-21
0.15 - -
0.075 2-8 2-8
Bitumen content % by mass
Min 4.5
of total mix2 Min 4.0
Bitumen grade 65 or 90 65 to 90
Note: 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

500.7.3 Mixture design

500.7.3.1 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

0
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 faces of the
specimen
Percent air voids 3-6
Percent voids in mineral aggregate (VMA) See Table 500-12 below
Percent 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)

2
Nominal Maximum Minimum VMA, Percent Related to Design Air Voids, Percent
1
Particle Size (mm) 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 percent.

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2. Interpolate minimum voids in the mineral aggregate (VMA) for design air voids values
between those listed.

500.7.3.2 Binder content - The binder content shall be optimized 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.

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.

500.7.3.3 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 proportions of
each in the combined gradings.

(v) The results of tests enumerates 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 should be forwarded to the engineer for approval before the placing of the
material.

500.7.3.4 Plant trials – permissible variation in job mix formula - Once the laboratory
job mix formula is approved, the contractor shall carry out plant trails at the mixer to
establish that the plant can be set up to produce a uniform mix conforming to the approved
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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.

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.

Table 500-13. Permissible variations from the job mix formula

Description Permissible variation
Base/binder course Wearing course
Aggregate passing 19mm sieve or larger  8%  7%
Aggregate passing 13.2 mm, 9.5 mm  7%  6%
Aggregate passing 4.75 mm  6%  5%
Aggregate passing 2.36 mm, 1.18mm, 0.6mm  5%  4%
Aggregate passing 0.3mm, 0.15mm  4%  3%
Aggregate passing 0.075 mm  2%  1.5%
Binder content  0.3%  0.3%
Mixing temperature  100C 100C

500.7.3.5 Laying 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, the compacted all in accordance with clause 500.1. 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 methodology are 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 methodology 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.

500.7.4 Construction operations

500.7.4.1 Weather and seasonal limitations - The provisions of clause 500.1.5.1 shall
apply.

500.7.4.2 Preparation of base - The base on which Dense Graded Bituminous Material is
to be laid shall be prepared in accordance with sections 500 and 900 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.

500.7.4.3 Geosynthetics - Where Geosynthetics are specified in the contract this shall be
in accordance with the requirements stated in section 700.
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 500.7.4.4 Stress absorbing layer - Where a stress-absorbing layer is specified in the
contract, this shall be applied in accordance with the requirements of clause 500.22.

500.7.4.5 Prime coat - Where the material on which the dense bituminous macadam is to
be laid other than a bitumen bound layer, a prime coat shall be applied, as specified, in
accordance with the provisions of clause 500.2, or directed by the engineer.

500.7.4.6 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 500.3, or directed by the engineer.
500.7.4.7 Mixing and transportation of the mixture - The provisions as specified in
clauses 500.1.3 and 500.1.4 shall apply.

500.7.4.8 Spreading - The provisions of clauses 500.1.5.3 and 500.1.5.4 shall apply.

500.7.4.9 Rolling - The general provisions of clauses 500.1.6 and 500.1.7 shall apply, as
modified by the approved laying trials. The compaction process shall be carried bout 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.

500.7.5 Opening to traffic - 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.

500.7.6 surface finish and quality control of work - The surface finish of the completed
construction shall conform to the requirements of clause 900.2. All materials and
workmanship shall comply with the provisions set out in section 900 of this specification.

500.7.7 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of section 100.

500.7.8 Measurement for payment - 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 directed by
the engineer.

500.7.9 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 500.1.8.8.2 (i) to (xi). The
rate shall include the provision of bitumen, at 4.25 percent, 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.

500.8. SPECIFICATIONS FOR SEMI – DENSE BITUMINOUS CONCRETE(U.V-

November 2000)

500.8.1 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 25 mm to 100 mm
in thickness.

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500.8.2 Materials
500.8.2.1 Bitumen - The bitumen shall be paving bitumen of penetration grade complying
with Indian Standard Specification for Paving Bitumen, IS: 73 and of the penetration
indicated in Table 500-15, for semi dense bituminous concrete, or this bitumen as
modified by one of the methods specified in clause 500.21, 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.
500.8.2.2 Coarse aggregates - The coarse aggregates shall be generally as specified in
clause 500.7.2.2, except that the aggregates shall satisfy the physical requirements of
Table 500.14.

500.8.2.3 Fine aggregates - The fine aggregates shall be all as specified in clause
500.7.2.3.

500.8.2.4 Filler - Filler shall be generally as specified in clause 500.7.2.4. 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.

500.8.2.5 Aggregate grading and binder content - When tested in accordance with IS:
2386 Part 1 (wet sieving method), the combined grading of the coarse and fine aggregates
and added filler shall fall within the limits shown in Table 500-15 for gradings 1 or 2 as
specified in the contract.

500.8.3 Mixture design

500.8.3.1 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.

Table 500-14. Physical requirements for coarse aggregate for semi dense bituminous
concrete pavement layers
Property Test Specification
1 Max 5% passing 0.75 mm
Cleanliness (dust) Grain size analysis
sieve
Flakiness and elongation
Particle shape 2 Max 30%
Index (combined)
3
Los Angeles Abrasion Value Max 35%
Strength* 4
Aggregate Impact value Max 27%
5
Polishing Polished stone Value Min 55
6
Soundness
Durability Sodium Sulphate Max 12%
Magnesium Sulphate Max 18%
7
Water absorption Water absorption Max 2%
Coating and stripping of
Stripping 9 Minimum retained coating
bitumen aggregate mixtures
95%
8
Water sensitivity** Retained tensile strength 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 samples)
3. IS: 2386 Part 4* 8. AASHTO T 283**
4. IS: 2386 Part 4* 9. IS: 6241
5. BS: 812 Part 114

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* Aggregate may satisfy requirements of either of these two tests
** the water sensitivity test is only required if the minimum retained coating in the stripping
test is less than 95%.

The requirements for minimum per cent voids in mineral aggregate (VMA) are set out in
Table 500-12.

500.8.3.2 Binder content - The binder content shall be optimised to achieve the
requirements of the mixture set out in Table 500-16 and the traffic volume as specified in
the contract. The Marshall method for determining the optimum binder content shall be
adopted as described in the Asphalt Institute Manual MS-2, replacing the aggregates
retained on the 26.5 mm sieve and retained on the 22.4 mm sieve, where approved by the
engineer.

Table 500-15. Composition of semi dense bituminous concrete pavement layers

Grading 1 2
Nominal aggregate size 13 mm 10 mm
Layer Thickness 35 – 40 mm 25 – 30 mm
1
IS Sieve (mm) Cumulative % by weight of total aggregate passing
45
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 mix2 Min 4.5 Min 5.0
Bitumen grade (pen) 65* 65*
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.
* 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

0
Minimum stability (kN at 60 C) 8.2
Minimum flow (mm) 2
Maximum flow (mm) 4
75 blows on each of the two faces of the
Compaction level (Number of blows)
specimen
Percent air voids 3-5
Percent voids in mineral aggregate (VMA) See Table 500-12
Percent voids filled with bitumen (VFB) 65 - 78

500.8.3.3 Job mix formula - The procedure for formulating the job mix formula shall be
generally as specified in clause 500.7.3.3 and results of tests enumerated in Table 500-16
as obtained by the contractors.

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500.8.3.4 Plant trials – permissible variation in job mix formula - The requirements for
plant trials shall be all as specified in clause 500.7.3.4, and permissible limits for variation
as shown in Table 500-13.

500.8.3.5 Laying trials - The requirements for laying trials shall be all as specified in
clause 500.7.3.5.

500.8.4 Construction operations

500.8.4.1 Weather and seasonal limitations -The provisions of clause 500.1.5.1 shall
apply.
500.8.4.2 Preparation of base - The surface on which the Semi Dense Bituminous
material is to be laid shall be prepared in accordance with clauses 500.1 and 900.2 as
appropriate or as directed by 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.

500.8.4.3 Geosynhetics - Where Geosynthetics are specified in the contract this shall be
in accordance with the requirements stated in section 700.

500.8.4.4 Stress absorbing layer - Where a stress-absorbing layer is specified in the

contract, this shall be applied in accordance with the requirements of clause 500.22.

500.8.4.5 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
500.3.

500.8.4.6 Mixing and transportation of the mixture - The provisions as specified in

clauses 500.1.3 and 500.1.4 shall apply.

500.8.4.7 Spreading - The general provisions of clauses 500.1.5.3 and 500.1.5.4 shall
apply.

500.8.4.8 Rolling - The general provisions of clauses 500.1.6 and 500.1.7 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.

500.8.5 Opening to traffic - 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 approval of
the engineer in writing.

500.8.6 Surface finish and quality control - The surface finish of the completed
construction shall conform to the requirements of clause 900.2. All materials and
workmanship shall comply with the provisions set out in section 900 of this specification.

500.8.7 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of section 100.

500.8.8 Measurement for payment - The measurement shall be all as specified in

clause 500.7.8.

500.8.9 Rate - The contract unit rate shall be all as specified in clause 500.7.9, except
that the rate shall include the provision of bitumen at 4.75 percent, by weight of total
mixture. The variance in actual percentage of bitumen used will be assessed and the
payment adjusted up or down, accordingly.

- 73 -
500.9. SPECIFICATIONS FOR BITUMINOUS CONCRETE (U.V-NOVEMBER-2000)
500.9.1 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 layer shall be 25 mm to 100 mm in thickness.

500.9.2 Materials
500.9.2.1 Bitumen - The bitumen shall be paving bitumen of penetration grade complying
with Indian Standard Specification for Paving Bitumen, IS:73 and of the penetration
indicated in Table 500-18, for bituminous concrete, or this bitumen as modified by one of
the methods specified in clause 500.21, 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.

500.9.2.2 Coarse aggregates - The coarse aggregates shall be generally as specified in

clause 500.7.2.2, except that the aggregates shall satisfy the physical requirements of
Table 500-17.

500.9.2.3 Fine aggregates - The fine aggregates shall be all as specified in clause
500.7.2.3.

500.9.2.4 Filler - Filler shall be generally as specified in clause 500.7.2.4. 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.

500.9.2.5 Aggregate grading and binder content - When tested in 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 grading 1
or 2 as specified in the contract.

500.9.3 Mixture design

500.9.3.1 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 500-19.

The requirements for minimum per cent voids in mineral aggregate (VMA) are set out in
Table 500-12.

500.9.3.2 Binder content - The binder content shall be optimised to achieve the
requirements of the mixture set out in Table 500-19 and the traffic volume as specified in
the contract. The Marshall method for determining the optimum binder content shall be
adopted as described in the Asphalt Institute Manual MS-2, replacing the aggregate
retained on the 26.5 mm sieve and retained on the 22.4 mm sieve, where approved by the
engineer.

500.9.3.3 Job mix formula - The procedure for formulating the job mix formula shall be
generally as specified in clause 500.7.3.3 and the results of tests enumerated in Table
500-19 as obtained by the contractors.

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Table 500-17. Physical requirements for coarse aggregate for bituminous concrete
pavement layers
Property Test Specification
1 Max 5% passing 0.75 mm
Cleanliness (dust) Grain size analysis
sieve
Flakiness and elongation Max 30%
Particle shape 2 2
Index (combined) (combined)
3
Los Angeles Abrasion Value Max 30%
Strength* 4
Aggregate Impact value Max 24%
5
Polishing Polished Stone Value Min 55
6
Soundness
Durability Sodium Sulphate Max 12%
Magnesium Sulphate Max 18%
7
Water absorption Water absorption Max 2%
Coating and Stripping of
Stripping 9 Minimum retained coating
Bitumen Aggregate Mixtures
95%
8
WATER Sensitivity** Retained Tensile Strength 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 samples)
3. IS: 2386 Part 4* 8. AASHTO T 283**
4. IS: 2386 Part 4* 9. IS: 6241
5. BS: 812 Part 114
* Aggregate may satisfy requirements of either of these two tests
** The water sensitivity test is only required if the minimum retained coating in the stripping
test is less than 95%.

500.9.3.4 Plant trials – permissible variation in job mix formula - The requirements for
plant trials shall be all as specified in clause 500.7.3.4, and permissible limits for variation
as shown in Table 500-13.

500.9.3.5 Laying trials - The requirements for laying trials shall be all as specified in
clause 500.7.3.5.

500.9.4.1 Weather and seasonal limitations - The provisions of clause 500.1.5.1 shall
apply.

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Table 500-18. Composition of bituminous concrete pavement layers
Grading 1 2
Nominal aggregate size 19 mm 13 mm
Layer Thickness 50 – 65 mm 30 – 45 mm
1
IS Sieve (mm) Cumulative % by weight of total aggregate passing
45
37.5
26.5 100
19 79 - 100
13.2 59 - 79 100
9.5 52 - 72 90 - 100
4.75 35 - 55 35 - 51
2.36 28 - 44 24 - 39
1.18 20 - 34 15 - 30
0.6 15 - 27 -
0.3 10 - 20 9-19
0.15 5 - 13 -
0.075 2-8 3-8
Bitumen content % by mass of
2
total mix 5.0 – 6.0 5.0 – 7.0
Bitumen grade (pen) 65 65

Notes:
1. The combined aggregate grading shall not vary from the low limit on one sieve to the
high limit on the adjacent sieve.
2. Determined by the Marshall method.
Table 500-19. Requirements for bituminous pavement layers
0
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 faces of the
specimen
Percent air voids 3-6
Percent voids in mineral aggregate (VMA) See Table 500-12
Percent voids filled with bitumen (VFB) 65 - 75
0
Loss of stability on immersion in water at 60 C Min. 75 percent retained strength
(ASTM D 1075)

500.9.4.2 Preparation of base - The surface on which the bituminous concrete is to be

laid shall be prepared in accordance with clauses 500.1 and 900.2 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.

500.9.4.3 Geosynthetics - Where Geosynthetics are specified in the contract this shall be
in accordance with the requirements stated in section 700.

500.9.4.4 Stress absorbing layer - Where a stress absorbing layer is specified in the
contract, this shall be applied in accordance with the requirements of clause 500.22.

500.9.4.5 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
500.3.

500.9.4.6 Mixing and transportation of the mixture - The provisions as specified in

clauses 500.1.3 and 500.1.4 shall apply.
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500.9.4.7 Spreading - The general provisions of clauses 500.1.5.3 and 500.1.5.4 shall
apply.

500.9.4.8 Rolling - The general provisions of clauses 500.1.6 and 500.1.7 shall apply, as
modified by the approved laying trials.

500.9.5 Opening to traffic - 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 approval of
the engineer in writing.
500.9.6 Surface finish and quality control - The surface finish of the completed
construction shall conform to the requirements of clause 900.2. All materials and
workmanship shall comply with the provisions set out in section 900 of these
specifications.

500.9.7 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of section 100.

500.9.8 Measurement for payment - The measurement shall be all as specified in clause
500.7.8.

500.9.9. Rate - The contract unit rate shall be all as specified in clause 500.7.9, except
that the rate shall include the provision of bitumen at 5.0 percent, by weight of total
mixture. The variance in actual percentage of bitumen used will be assessed and the
payment adjusted up or down, accordingly.

500.10 SPECIFICATIONS FOR SURFACE DRESSING (U.V-November 2000)

500.10.1 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.

500.10.2 Materials
500.10.2.1 Binder - The binder shall have a kinematic viscosity lying in the range 1 x 104
to 7 x 105 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

500.10.2.2 Aggregates - The chips shall conform to the requirements of clause

500.4.2.2., 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 grading given in Table 500-21.

500.10.2.3 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.

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Table 500-20. Nominal rates of spread for binder and chippings(1)
Nominal chipping size Binder (Penetration grade Chips
Mm bitumen) Kg/m2 Cum/m2
19 1.2 0.015
13 1.0 0.010
10 0.09 0.008
6 0.075 0.004
Note: 1.These rates of spread are for pricing purposes –see clause 500.10.2.3 and clause
500.10.8
2. For emulsion, these rated 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.
500.10.2.4 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.
500.10.2.5 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 percent of paving bitumen by weight of chips in a suitable
mixer, the chips beings heated to 1600C 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.

500.10.3 Construction operations

500.10.3.1 Weather and seasonal limitations - Clause 500.1.5.1 shall apply.

Table 500-21. Grading requirements for chips for surface dressing

IS Sieve Cumulative percent by weight of total agregate passing for the
designation following nominal sizes
mm 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
0.6 - - - 0-2
0.075 0-1.5 0-1.5 0-1.5 0-1.5
Minimum 65 % Passing 19 Passing 13.2 Passing 9.5 Passing 6.3
by weight of mm, retained mm, retained mm, retained mm, retained
aggregate 13.2 mm 9.5 mm 6.3 mm 3.35 mm

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500.10.3.2 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 500.1 or as directed by the engineer. Prime coat, where
needed, shall be provided as per clause 500.2 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).

500.10.3.3 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 500.10.23.

Table 500-22. Spraying temperatures for binders

Binder grades Whirling spray jets Slot jets
0 0 0 0
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

500.10.3.4 Application of stone chips - The equipment and general 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 Construction and Supervision of
Bituminous Works. Immediately after application of the binder, clean, dry chips (in the
case of emulsion binder the chipping may be damp) shall be spread uniformly on the
surface so as to cover the surface completely with a single layer of chips.

500.10.3.5 Rolling - Rolling of the chips should preferably be carried out by a pneumatic
tyred roller in accordance with clause 500.1.6 and clause 500.1.7. traditional steel
wheeled rollers tend to crush the aggregates and if their use cannot be avoided their
weight should be limited t 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.

500.10.3.6 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 500.10.3.3 to 500.10.3.5.

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500.10.4 Opening to traffic - Traffic shall not be permitted to run on any newly surface
dressed area until the following day. In special circumstances, however, the engineer,
may 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.

500.10.5 Surface finish and quality control of work - The surface finish of construction
shall conform to the requirements of clause 900.2.

For control on the quality of materials supplied and the works carried out, the relevant
provisions of section 900 shall apply.

500.10.6 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12.

500.10.7 Measurement for payment - Each coat of surface dressing shall be measured
as finished work, for the area instructed to be covered, in square metres.

500.10.8 Rate - The contract unit rate for surface dressing, based on the notional rates of
spread for binder and each size of chipping given in clause 500.10.2.3, 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 500.1.8.8.2 (i) to (xi).

500.11. SPECIFICATIONS FOR OPEN-GRADED PREMIX SURFACING (U.V-November

2000)
500.11.1 Open-graded Premix Surfacing using Penetration Bitumen or Cutback.

500.11.1.1 Scope - This work shall consist of the preparation, laying and compaction of an
open-graded premix surfacing material of 20 mm 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.

500.11.1.2 Materials
500.11.1.2.1 Binder - The binder shall be a penetration bitumen of a suitable gtradre as
specified in the contract, or as directed by the engineer, and satisfying the requirements of
IS:73.

500.11.1.2.2 Aggregate - The aggregate shall conform to clause 500.4.2.2 except that the
water absorption shall be limited to a maximum of 1 per cent. The Polished Stone Value,
as measured by the test in BS 812-(Part 114), shall not be less than 55.

500.11.1.2.3 Proportioning of materials - The materials shall be proportioned in

accordance with Table 500-23.

500.11.1.3 Construction operations

500.11.1.3 Weather and seasonal limitations - Clause 500.1.5.1 shall apply.

500.11.1.3.2 Preparation of surface - The under lying 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 500.1. A prime coat where needed
shall be applied in accordance with clause 500.2 as directed by the engineer.
- 80 -
Table 500-23. Quantities of materials required for 10 m2 of road surface for 20 mm thick
open graded premix surfacing using penetration bitumen or cutback
Aggregates
a. Nominal Stone size 13.2 mm (passing 22.4 mm sieve 0.18 m3
and retained on 11.2 mm sieve)
3
b. Nominal Stone size 11.2 mm (passing 13.2 mm sieve 0.09 m
and retained on 5.6 mm sieve)
3
Total 0.27 m
Binder (quantities in terms of straight run bitumen)
3
a. For 0.18 m of 13.2 mm nominal size stone at 52 kg 9.5 kg
3
bitumen per m
b. For 0.09 m3 of 11.2 mm nominal size stone at 56 kg 5.1 kg
3
bitumen per m
Total 14.6 kg

500.11.1.3.3 Tack coat - A tack coat complying with clause 500.3, shall be applied over
the base preparatory to laying of the surfacing.

500.11.1.3.4 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 1500C to 1630C
and that of the aggregate in the range of 155 0C to 1630C provided that the difference in
temperature between the binder ands aggregate at no time exceeds 140C. 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
1300C and 1600C.

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.

500.11.1.3.5 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 pup depressions, if any. The cross-fall should be
checked by means of camber boards and irregularities leveled 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 towards 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 tot he wheels. In no case shall fuel/lubricating oil be used 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 ion
every respect before the temperature of the mix falls below 1000C. Joints along and
transverse to the surfacing laid and compacted earlier shall be cut vertically to heir full

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depth so as to expose fresh surface which shall be painted with a in coat of appropriate
binder before the new mix is placed against it.

500.11.1.3.6 Seal coat - A seal coat conforming to clause 500.13 of the type specified in
the contract shall be applied to the surface immediately after laying the surfacing.

500.11.1.4 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 500.13.4.

500.11.1.5 Surface finish and quality control of work - The surface finish of
construction shall conform to the requirements of clause 900.2. For control of the quality
of materials supplied and the works carried out, the relevant provisions of section 900
shall apply.

500.11.1.6 Arrangements for traffic - During the period of construction, arrangement of

traffic shall be made in accordance with the provisions of clause 100.12.

500.11.1.7 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.

500.11.1.8 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 500.1.8.8.2. (i) to (xi).

500.11.2 Open graded premix surfacing using cationic bitumen emulsion

500.11.2.1 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 emulsion on a previously prepared surface, in
accordance with the requirements of these specifications, to serve as a wearing course.

500.11.2.2 Materials
500.11.2.2.1 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 percent 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.

500.11.2.2.2 Aggregate - The requirements of clause 500.11.1.2.2 shall apply.

500.11.2.3 Proportioning of materials

The materials shall be proportioned as quantities given in Tables 500-24 and 500-25.

Table 500-2. 4. Quantities of aggregate for 10 M2 area

A) Premix Carpet:
3
a. Coarse aggregate nominal 13.2 mm size; passing IS 0.18 m
22.4 mm sieve and retained on IS 11.2 mm sieve
3
b. Coarse aggregate nominal 11.2 mm size; passing IS: 0.09 m
13.2 mm sieve and retained on IS 5.6 mm sieve
B. For seal coat:
Refer to clause 500.13

- 82 -
Table 500-25. Quantities of emulsion binder
2
For 10 m area
A) For Premix Carpet 20 to 23 kg
B) For Seal Coat:
a. For liquid seal coat 12 to 14 kg
b. For premix seal coat 10 to 12 kg

500.11.2.4 Construction operations

500.11.2.4.1 Weather and seasonal limitations - clause 500.1.5.1 shall apply except
that the minimum air temperature for laying shall be 10 0C. Cationic bitumen emulsions
shall not normally be stored below 00C

500.11.2.4.2 Preparation of surface - The underlying surface on which the premix

surfacing is to be laid shall be prepared, in accordance with the requirements of clause
500.4.3.2 for a newly primed surface, and in accordance with clause 500.7.4.2 where an
existing bituminous surface is to be overlaid.

500.11.2.4.3 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.

500.11.2.4.4 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 should 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 11.2 mm size aggregate shall be added,
followed by 5 to 6.5 kg of cationic bitumen emulsion. After the materials have been mixed
thoroughly, the mix shall be immediately transported to the laying site in suitable vehicles.
Too much mixing shall be avoided.

When mixed manually by sholves, with the approval of the engineer, 0.06 cu. 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
remaining quantify of emulsion are added and mixed. Too much mixing shall be avoided.

500.11.2.4.6 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 cross fall should be checked by means of camber boards and irregularities
leveled out. Too much raking is to be avoided.

- 83 -
The rolling shall start immediately after laying the premix. A smooth wheeled tandem
roller of 8-10 tonnes shall be used, unless the engineer, based on the results of laying
trials approves other compaction methods, 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.

500.11.2.4.7 Seal coat - A seal coat, conforming to clause 500.10 or clause 500.13, as
specified in the contract, shall be applied 4 to 6 hours after laying the premix carpet.

500.11.2.5 Opening to traffic - Traffic should not be allowed over the premix surface with
or without seal coat, for 6 to 8 hours after rolling. In case of single lane roads, traffic shall
be allowed onto the surface once it has reached ambient temperature, but speed must be
rigorously restricted to not more than 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.

500.11.2.6 Surface finish and quality control - The surface finish of construction shall
conform to the requirements of clause 900.2.

For control of the quality of materials supplied and the works carried out, the relevant
provisions of section 900 shall apply.

500.11.2.7 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12.
500.11.2.8 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.

500.11.2.9 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 500.1.8.8.2 (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, 13 kg 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.

- 84 -
500.12 SPECIFICATIONS FOR CLOSE- GRADED PREMIX SURFACING/MIXED SEAL
SURFACING (U.V-November 2000)
500.12.1 Scope
500.12.1.1 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.

500.12.1.2 Close graded premix surfacing shall be of Type A or Type Bitumen as specified
in the contract documents.
500.12.2 Materials
500.12.2.1 Binder - The provisions of clause 500.11.1.2.1 shall apply.

500.12.2.2 Coarse aggregates - The provisions of clause 500.11.1.2.2 shall apply.

500.12.2.3 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.

500.12.2.4 Aggregate gradation - The coarse and fine aggregates shall be so graded or
combined as to conform to one or he other grading shown in Table 500-26, as specified in
the contract.

Table 500-26. Aggregate gradation

Cumulative per cent by weight of total aggregate passing
IS Sieve Designation (mm) Type A Type B
13.2 mm - 100
11.2 mm 100 88 - 100
5.6 mm 52 - 88 31 – 52
2.8 mm 14 – 38 5 – 25
0.090 mm 0-5 0-5
500.12.2.5 Proportioning of materials - The total quantity of aggregates used for Type A
or Bitumen 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 of Type A and Type Bitumen surfacing
respectively.

500.12.3 Construction operations - The provisions of clause 500.11.1.3.1 through

500.11.1.3.5 shall apply.

500.12.4 Opening to traffic - 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.

500.12.5 Surface finish and quality control of work - The surface finish of construction
shall conform to the requirements of clause 900.2. for control on the quality of materials
supplied and the works carried out, the relevant provisions of section 900 shall apply.

500.12.6 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be in accordance with the provisions of clause 100.12.

500.12.7 Measurements for payment - 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

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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.

500.12.8 Rate - The contract unit rate for close-graded premix surfacing, Type A or
bitumen shall be payment in full for carrying out the required operations including full
compensation for all components listed in clause 500.1.8.8.2 (i) to (xi).

500.13. SPECIFICATIONS FOR SEAL COAT(U.V-November 2000)

500.13.1 Scope
500.13.1.1 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).

500.13.1.2 Seal coat shall be of either of the two types specified below:
(A) Liquid seal coat comprising of an application of a layer of bituminous binder followed
by a cover of stone chips.

(B) Premixed seal coat comprising of a thin application of fine aggregate premixed with
bituminous binder.

500.13.2 Materials
500.13.2.1 Binder - The requirements of clauses 500.11.1.2.1 and 500.11.2.2.1 shall
apply.
The quantity of bitumen per 10 square metres, shall be 9.8 kg for Type A, and 6.8 kg for
Type Bitumen seal coat. Where bituminous emulsion is used as a binder the quantities for
Type A and Type Bitumen seal coats shall be 15 kg and 10.5 kg respectively.

500.13.2.2 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 6.7 mm 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.

500.13.2.3 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 form dust,
soft or flaky/elongated material, organic matter or other deleterious substances. The
aggregate shall pass 2.36-mm sieve and be retained on 180micron sieve. The quantity
used for premixing shall be 0.06 cubic metres per 10 square metres area.

500.13.3 Construction operations

500.13.3.1 Weather and seasonal limitations - The requirements of clause 500.1.5.1
shall apply.

500.13.3.2 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.

500.13.3.3 Construction of Type A seal coat - Bitumen shall be heated to 1500C – 1630
C and sprayed at the rate specified on the dry surface in a uniform manner with a self-
propelled mechanical sprayer.

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

Immediately after the application of the cover material, the entire surface shall be rolled
with a 8-10 smooth wheeled steel roller, 8 – 10 tonnes 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 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 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.

500.13.3.4 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
aggregate shall be dry and suitably heated to a temperature between 1500 c and 1650 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 surface 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.

500.13.4 Opening to traffic - In the case of Type B seal coat, traffic may be allowed
soon after final rolling when the premixed materials 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 immediately after rolling, but in such cases traffic
speed shall be rigorously limited to 16 km per hour until the following day.

500.13.5 Surface finish and quality control of work - The surface finish of construction
shall conform to the requirements of section 900.

For control on the quality of materials supplied and the works carried out, the relevant
provisions of section 900 shall apply.

500.13.6 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of section 100.

500.13.7 Measurement for payment - 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.

500.13.8 Rate - The contract unit rate for seal coat Type A or B shall be payment in full for
carrying out the required operations including full compensation for all components listed
in clause 500.1.8.8.2 (i) to (xi).

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500.14 SPECIFICATIONS FOR SUPPLY OF STONE AGGREGATES FOR PAVEMENT
COURSES (U.V- November 2000)
500.14.1 Scope - This specification 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 specification clauses for the individual
items given elsewhere in this specification.

500.14.2 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
Designation of sieve Designation of sieve
Sl.No. Nominal size of aggregate through which the on which the
aggregates shall aggregates shall be
wholly pass wholly retained
i. 75 mm 106 mm 63 mm
ii. 63 mm 90 mm 53 mm
iii. 45 mm 53 mm 26.5 mm
iv. 26.5 mm 45 mm 22.4 mm
v. 22.4 mm 26.5 mm 13.2 mm
vi. 13.2 mm 22.4 mm 11.2 mm
vii. 11.2 mm 13.2 mm 6.7 mm
viii. 6.7 mm 11.2 mm 2.8 mm

500.14.3 Stacking
1. Coarse aggregates - Only the aggregates satisfying the specification requirements
shall be conveyed tot he roadside and stacked. Each size of aggregate shall be stacked
separately. Likewise, materials obtained from different quarry sources shall 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 road way on even clear hard ground,
or 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 engineer shall reject the stockpile. Materials shall not be stacked
in locations liable to inundation or flooding.

The engineer shall approve the dimensions of the stockpiles and their location. 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.
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500.14.4 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.
One test for each specified property for every five tonnes, subject to a
Stone filler
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.

500.14.5 Measurement for payment - 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.

Table 500-28. Percent reduction in volume of aggregates

Percentage reduction in volume
Sl.No. Standard size 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 aggregates 5.0

500.14.6 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.

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500.15. SPECIFICATIONS FOR MASTIC ASPHALT (U.V-November 2000)
500.15.1 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.
500.15.2 Materials
500.15.2.1 Binder - Subject to the approval of the engineer, the binder shall be a paving
grade bitumen meeting the requirements given in Table 500-29.

500.15.2.2 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 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 500-29. Requirements for physical properties of binder

Property Test method Requirement
0
Penetration at 25 C IS 1203 15  5
0
Softening point, C IS 1205 65  10
0
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

Table 500-30. Grade and thickness of mastic asphalt paving, and grading of coarse
aggregate
Application Thickness range Nominal size of Coarse aggregate
(mm) coarse aggregate content, % by mass of
(mm) total mix
Roads and carriageways 25 – 50 13 40  10
Heavily stressed areas
i.e. junctions and toll 40 - 50 13 45  10
plazas
Nominal size of coarse 13 mm
aggregate Cumulative % passing by weight
IS Sieve (mm)
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 lime stone 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.

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They grading of the fine aggregate inclusive of filler shall be as given in Table 500-31.

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

500.15.3 Mixing design

500.15.3.1 Hardness number - The mastic asphalt shall have a hardness number at the
time of manufacture of 60 to 80 at 250C prior to the addition of coarse aggregate and 10 to
20 at 250C at the time of laying after the addition of coarse aggregate.

500.15.3.2 Binder content - The binder content shall be so fixed as to achieve the
requirements of the mixture specified in clause 500.15.3.1 and shall be in the range of 14
to 17 percent 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 0.600 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

500.15.3.3 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 locating 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.

500.15.4 Construction operations

500.15.4.1 Weather and seasonal limitations - The provisions of clause 500.1.5.1 shall
apply, except that laying shall not be carried out when the air temperature at the surface
on which the Mastic Asphalt is to be laid is below 100C.

500.15.4.2 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
500.1 or 900.2 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.

500.15.4.3 Tack coat - A tack coat in accordance with clause 500.3 shall be applied on
the base or as directed by the engineer.

500.15.4.4 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 1700C to 2100C. Required quantity of bitumen shall be heated
to 1700C to 1800C and added to the heated aggregates. They shall be mixed and cooked

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in an approved type of mechanically agitated mastic cooker for some time till the materials
are thoroughly mixed. Initially the filler along is to be 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 2100C.

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 1750C and not more than 2100C, thoroughly incorporated with the requisite
quantity of coarse aggregates and mixed continuously. Mixing shall be continued until
laying operations are completed so as to maintain the coarse aggregates in suspension.
At no stage during the process of mixing shall the temperature exceed 2100C.

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.

500.15.4.5 Spreading - The mastic asphalt shall be laid, normally in one coat, at a
temperature between 1750C and 2100C 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 blowholes that appear in the surface shall be punctured while
the material is hot, and the surface made good by further floating.

500.15.4.6 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.

500.15.4.7 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 9.5 mm size (passing the 13.2 mm sieve and retained on the 6.7 mm sieve)
subject tot he 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 other wise pressed into the
surface of the mastic layer when the temperature of the mastic asphalt is not less than
1000C.

500.15.5 Opening to traffic - 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.

500.15.5.6 Surface finish and quality control of work - The surface finish of the
completed construction shall conform to the requirements of clause 900.2.
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For control of the quality of materials supplied and the works carried out, the relevant
provisions of section 900 shall apply.

The surface of the mastic asphalt, tested with a straight edge 3.0 m long, placed parallel to
the centre line of the carriageway, shall have no depression greater than 7 mm. The
same limit shall also apply to the transverse profile when tested with a camber template.

500.15.5.7 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12.

500.15.8 Measurement for payment - 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.

500.15.9 Rate - The contract unit rate for mastic asphalt shall be payment in full for
carrying out the required operations including full compensation for all comp9onenets
listed under clause 500.1.8.8.2 (i) to (ix).

500.16. SPECIFICATIONS FOR SLURRY SEAL (U.V-November 2000)

500.16.1 Scope - Slurry seal are mixtures of fine aggregate, Portland cement filler,
bitumen emulsion and additional water. When freshly mixed, they have a thick
consistency and can be spread to a thickness of 1.5-5 mm. They may be used to seal
cracks, arrest fretting and fill voids and minor depressions, to provide a more even riding
surface or a base for further treatment; they may also be used on top of a single coat
surface dressing.

500.16.2 Materials - The material for slurry seal immediately prior to mixing shall conform
to the following requirements.

500.16.2.1 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:Part1 should be used to obtain very early resistance to traffic and
rain. Generally, emulsion for slurry seal should be capable of producing a slurry that will
develop early resistance to traffic and rain and is sufficiently stable to permit mixing with
the specified aggregate, without breaking during the mixing and laying processes. If
approved by the engineer, a slow setting emulsion may be used.

500.16.2.2 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 500 ppm, the engineer may reject it, or order the contractor to
conduct a trial emulsion mix to demonstrate that it does not cause early separation.

500.16.2.3 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).

500.16.Additives - It is usual to use ordinary Portland cement, hydrated lime or other

additives to control consistency, mix segregation and setting rate. The proportion of the
additive should not normally exceed 2 per cent by weight of dry aggregates.
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500.16.3 Mixture design - 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.

500.16.4 Construction operations

500.16.4.1 Weather and seasonal limitations - Clause 500.1.5.1 shall apply.
Table 500-33. Aggregate grading, binder content and approximate coverage rate
Sieve Size (mm) Percentage by mass passing finished thickness of sealing
5 mm 3 mm 1.5 mm
9.5 100 - -
4.75 90 - 100 100 -
3.35 - 80 – 100 100
2.36 65 – 90 75 – 100 95 – 100
1.18 45 – 70 55 – 90 70 – 95
0.600 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 – 21 5 – 15 5 – 15
Quantity of residual
binder, percentage by 7.5 – 13.5 10 – 16 12 – 20
mass of aggregate
Approximate
2
coverage rate (kg.m ) 8 - 15 4-6 2-4
500.16.4.2 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 500.1.

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
removed by suitable means, and the surface shall be swept free of all loose material.

500.16.4.3 Tack coat - If required by the engineer, a tack coat may be applied prior tot he
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.

500.16.4.4 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.

- 94 -
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.

500.16.4.5 Application - Transverse joints for ;machine laid areas 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.

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.

Handwork 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 squeezes 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
sprayed applied mechanically, or for hand laying by a hand operated pressure sprayer,
unless otherwise approved by the engineer.

500.16.4.6 Rolling -The need for rolling shall be as instructed by the engineer. Where
rolling is required, a pneumatic-tyred rollier 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 occure.

500.16.5 Opening to traffic

Masking shall be removed after the slurry seal has been applied, without damage to the
edge of the sufacing, and before opening the orad or footway to traffc.

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 aminimum
period of 2 hours and if necessary the lane shall be sept again. The monitoring shall
continue until the slurry seal has reached sufficient stability to carry unrestricted traffic. If
there are signs of cistress, 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.
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Further operations to remove subsequently loosed aggregate shall be carried out over the
next 48 hours. The areas treated and adjacent side roads, foorways and paved areas
shall be kept substantially free of loose aggregate for a period of 30 days after completion
of the work.

500.16.6 Surface finish and quality control of work.

Generally, the surface finish of the completed construction shall conform to the
requirements in section 900. 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 pf 3
mm beneath a 1 metre straight edge due to scrapping, 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.

500.16.7 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12.

500.16.8 Measurement for payment - Slurry seal shall be measured as finished work as
specified, in square metres.

500.16.9 Rate - The contract unit rate of slurry seal shall be payment in full for carrrying
out the required operations including full compensation for all components listed clause
500.1.8.8.2(I) to (xi).

500.17. SPECIFICATIONS FOR RECYCLING OF BITUMINUOS PAVEMENT (U.V-

November 2000)
500.17.1 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 aggregated 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 500.l9 subject to the
resultant mixes achieving the specified standards.

500.17.2 Reclaimed bituminous materials for central plant recycling

500.17.2.1 Proportion of reclaimed materials less than 10 percent - 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 clause
500.17.2.2 to 500.17.2.9 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 particle size of reclaimed material does not
exceed 40 mm.
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b) the mixed material shall comply with the requirements of clauses 500.4 or 500.7 as
appropriate.

500.17.2.2 Proportions of reclaimed materials greater than 10 percent - Reclaimed

bituminous material of an amount greater than 10 percent, may be used in the production
of bituminous macadam and dense graded bituminous base and binder course material,
subject to the requirements of clauses 500.17.2.3 to 500.17.2.9 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-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.

500.17.2.3 Materials for recycled pavement - The recycled materials shall be a blend of
reclaimed and new materials proportioned to achieve 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 core 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.

500.17.2.4 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.

500.17.2.5 Aggregate evaluation - Mechanical sieve analysis (IS:2386, Part 1, 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 stockpiles planning’s 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.

500.17.2.6 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 BS2000: Part397, when tested in
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.
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 Table 500-34. Minimum recovered binder penetration of recycled mixture
Specified Grade of Binder Minimum Recovered Penetration Value of
(Penetration) Binder after Mixing
45 27
65 39
90 54

500.17.2.7 Rejuvenators - The use of rejuvenators, and a test to measure their

effectiveness, is described in clause 500.17.6.3.
500.17.2.8 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.

500.17.2.9 Combined aggregate grading - The blend of reclaimed and new aggregate
shall meet the grading criteria specified in the relevant parts of clause 500.4 or 500.7, 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.

500.17.3 Mixture design - The combined aggregate grading and binder content shall
comply with the relevant tables in clauses 500.4 or 500.7. For dense graded bituminous
mixtures the mixture design shall also comply with the requirements of Table 500-11.

500.17.4 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.

500.17.4.1 Cold removal process - In the cold process, the ripping and crushing
operations shall be carried out using scarifies, 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.

500.17.4.2 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 2000C for more than 5 minutes.

500.17.4.3 Stockpiling - In the cold process, the reclaimed bituminous pavement

material shall be stockpiles not exceeding 3m. 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.

500.17.5 Mixing and laying - Generally, the requirements of clauses 500.4.3 or 500.7.4
as appropriate shall apply.

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500.17.6 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 500.9.

500.17.6.1 Scope - In the process of repaving, 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 50 mm. 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.

500.17.6.2 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, planning, 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 2000C
for more than 5 minutes.

500.17.6.3 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 rejuvenator 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.

500.17.6.4 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.
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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
500.9.
500.17.6.5 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 500.9.2. 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.
500.17.6.6 Additional aggregate (Remix process) - The coarse aggregate, fine
aggregate and filler added to the Remixed mat4erial shall comply with the requirements of
clause 500.9.2.
500.17.6.7 New surfacing (Repave and Remix/repave processes) - New surfacing
material shall be bituminous concrete wearing course complying with clause 500.9, 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 1000C to 1500c.

500.17.6.8 Binder - The binder shall be recovered from samples taken from each layer of
material laid. The method of recovery shall be in accordance with BS200:Part 397 or an
equivalent test. The penetration of the binder shall be in the range 35-70 pen.

500.17.6.9 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 (Gmm) pf 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 (Gmb) will
naturally be less than Gmm. The percent air voids (Pa) in the specimen of the compacted
mixture given by
Gmm - Gmb
Pa = ---------------- x 100
Gmm
- 100 -
Should meet the requirements of air voids laid down in Table 500-19.
500.17.7 Opening to traffic - For recycled material forming the base or binder course
layer, clause 500.4.5 or 500.7.5 shall apply as appropriate. For recycled material forming
the wearing course layer, clause 500.9.5 shall apply.

500.17.8 surface finish and quality control - The surface finish of the completed
construction shall conform to the requirements of clause 900.2.
for control of the quality of materials supplied and the works carried out the relevant
provisions of section 900 shall apply.

500.17. 9 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12.

500.17.10 Measurement for payment - The recycled pavement work shall be measured
in cubic metres or tonnes of finished work as stated in the contract.

500.17.11 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
500.1.8.8.2 (i) to (xi).

500.18. SPECIFICATIONS FOR FOG SPRAY (U.V-November 2000)

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

500.18.2 Material - The bitumen emulsion shall be as specified in the contract or as

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

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.

500.18.3 Weather and seasonal limitations - Spraying shall not take place when the
temperature is below 100C, 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 500.18.4.2).

500.18.4 Construction operations

500.18.4.1 Equipment - The fog spray shall be applied by means of a self-propelled or
towed bitumen pressure sprayer. The spray bar should be protected from gusts of wind by
means of a hood.

500.18.4.2 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.

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500.18.4.3 Application - The fog seal shall be applied at a rate of 0.5-1.0 litres/m2, using
equipment such as pressure tank, flexible hose and spray bar or lance.
500.18.4 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 percent of
the emulsion by weight. The pre coated grit shall be allowed to be cured for at least one
week or until they become non-sticky and can be spread easily.

500.18.6 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.

500.18.7 Arrangements for traffic - During the spraying operations, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12. 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.

500.18.8 Measurement for payment - Fog spray and blinding (if used) shall be measured
in terms of surface area of application, for the area covered, in square metres.

500.18.9 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 500.1.8.8.2 (i) to (xi) as applicable to the work specified in
these specifications.

500.19. SPECIFICATIONS FOR BITUMINOUS COLD MIX (INCLUDING GRAVEL

EMULSION) - (U.V-November 2000)
500.19.1 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.

500.19.2 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 tot heir stability, in new work or major repair
work.

500.19.2.1 Materials
500.19.2.1.1 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-
2s, SS-1, SS-1h, CMS-2h, CSS-1 and CSS-1h. Alternatively a cutback bitumen as
specified in AASHTO M 82 (ASTM D2027) or ASTM D2026, namely MC 70, 250, 800 &
3000 and SC250, 800 and 3000 may be used, or, if approved by the engineer, an
equivalent material which conforms with IS:8887 and IS:217.

A general guides for the use of these binders is given in Table 500-35. However the final
selection shall be made only after laboratory evaluation 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.

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 Table 500 – 35. Uses of bitumen in cold mix
Emulsified bitumen Cutback bitumen
Type of construction Anionic Cationic Medium curing Slow Curing
(MC) (SC)
Cold-laid plant mix

MS-2h, HFMS-
MS-2, HFMS-
pavement base and
surfaces

HFMS-2s

CMS-2h

CSS-1h
CMS-2

CSS-1
SS-1h
SS-1

3000
250
800

250
800
300
2h

70
2
Open graded aggregate * * * *
well-graded aggregate * * * * * * * * * * *
patching, immediate use * * * * * * *
patching, stockpile * * * *

500.19.2.1.2 Aggregates - The aggregates shall comply with the requirements of clause
500.4.2.2 and 500.4.2.3. 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.

500.19.2.1.3 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.

500.19.2.2 Mixture design

500.19.2.2.1 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 500-37.

500.19.2.2.2 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.

Table 500-36. Aggregate grading and 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
0.075 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 Min 7 to Max 10

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 Table 500 – 37. Mixture requirements for designed cold mix
1 2
Parameter Emulsion Cutback
0
Minimum Stability (kN at 22.2 C) Emulsion 2.2 for paving 2.2 for maintenance
0
(kN at 25 C) Cutback 3.3 for paving
3 4
Percent maximum stability loss on soaking 50 25
Minimum flow (mm) 2 2
Compaction level (number of blows) 50 75
5
Per cent air voids 3-5 3-5
Percent voids in mineral aggregate (VMA) See Table 500 - 38
6
Percent minimum coating 50 -
Notes :
1. Using “Marshall method for emulsified asphalt – aggregate cold mixture design”.
2. Using “Marshall method for cut-back asphalt-aggregate cold mixture design”, Appendix
H, MS-14.
3. With vacuum saturation and immersion.
4. Four days soak at 250 C
5. Refers to total voids in the mix occupied by air and water.
6. Coating Test, Appendix F, MS-14.

500.19.2.2.3 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 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, 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) Spraying temperature of binder if appropriate.

While working out the job mix formula, the contractor shall ensure that it is based on a
correct and truly representative sample of the materials that will actually be used in the
work and that the 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
whom samples selected jointly with the engineer of all ingredients of the mix shall be
furnished by the contractor as requite by the former.

The approved job mix formula shall remain effective unless and until modified by the
engineer. Should a change in the source of materials be proposed, a new job mix formula
shall be established and approved by the engineer before actually using the materials.

Table 500.38. Minimum per cent voids in mineral aggregate (VMA)

Nominal Maximum Particle Size
Minimum VMA (percent)
IS Sieve (mm)
9.5 16.0
12.5 15.0
19.0 14.0
25.0 13.0
37.5 12.0
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500.19.2.2.4 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.

500.19.2.3 Construction operations

500.19.2.3.1 Weather and seasonal limitations - Construction with cold mix must not be
undertaken when ambient temperature below 100C 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 volatiles in cool and humid
conditions. Wind increases the rate of evaporation.

Table 500-39. Permissible variations from the job mix formula

Permissible variation
Description
Base/ binder course Wearing course
Aggregate passing 19 mm sieve or larger  8%  7%
Aggregate passing 13.2 mm, 9.5 mm  7%  6%
Aggregate passing 4.75 mm  6%  5%
Aggregate passing 2.36 mm, 1.18 mm, 0.6 mm  5%  4%
Aggregate passing 0.3 mm, 0.15 mm  4%  3%
Aggregate passing 0.075 mm  2%  1.5%
Binder content  0.3%  0.3%

500.19.2.3.2 Preparation of the base - The base on which cold mix is to be laid shall be
prepared, shaped and leveled to the required profile in accordance with clauses 500.1 And
900.2 as appropriate, and a prime coat, where specified, shall be applied in accordance
with clause 500.2 or as directed by the engineer.

500.19.2.3.3 Tack coat - A tack coat in accordance with clause 500.3 shall be applied
over the base on which the cold mix is to be laid where specified in the contract.

500.19.2.3.4 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 t 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.

500.19.2.3.5 Spreading - Designed cold mix shall be placed only when the specified
density can be obtained. The mixture shall not be placed on any wet surface or when
weather conditions will otherwise prevent its proper handling or finishing.

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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.

500.19.2.3.6 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 thickness being 25-100 mm and all compaction being in
accordance with clause 500.1.6 and clause 500.1.7. 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.
500.19.2.4 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.

500.19.2.5 surface finish and quality control of work - The surface finish of
construction shall conform to the requirements in section 900. For control of the quality of
supplied materials and the works carried out, the relevant provisions of section 900 shall
apply.

500.19.2.6 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions in section 100.

500.19.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.

500.19.2.8 Rate - The contract unit rate for designed cold mix shall be payment in full for
carrying out the required operations including full compensation for all components listed
in clause 500.1.8.8.2 (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.

500.19.3 SPECIFICATIONS FOR RECIPE COLD MIX (U.V-November 2000)

500.19.3 Recipe cold mix - This specification is based on BS 434 :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.

500.19.3.1 Materials
500.19.3.1.1 Binder - Emulsions of sufficient stability for mixing with the particular graded
aggregate should be used. Grades of emulsion quoted are in accordance with BS434 :
Part1 : 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.

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500.19.3.1.2 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 carried. Typical gradings are given in Table 500-40.

500.19.3.1.3 Aggregate grading and binder content - When tested in accordance with
IS:2336 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 engineer shall approve the actual quantity
of emulsion to be used after seeing the results of trial mixers made in the laboratory.

Table 500-40. Composition of recipe mixes

Nominal Size 40 40 14 6 -
(mm) and single course open textured open textured medium Fine coated
type of base course wearing textured
macadam course wearing
course
Allowable 75 – 100 75 – 100 31 – 50 21 – 30 15 - 20
Thickness
(mm)
IS Sieve
Cumulative % by weight of total aggregate passing
Size mm
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) (4)
Generally A2 – 57 or A2 – 50
Under some - - - A3 A3
Circumstances
(1)
Quantity 55 to 70 45 TO 65 70 to 90 85 to 100 100 to
(2) (3)
Litres/tonne 120
Note:
1. For pricing purposes the lower quantity in these ranges should be assumed.

2. With coarser grading quantity may sometimes be reduced to 80 litres/tonne and with
finer grading it may sometimes be increased up to 135 litres/tonne.

3. Use 0 - 70 litres/tonne of water as necessary.

4. A2 – 50 and A2 – 57 are British grades of emulsion and their grading system is

explained in the Manual

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500.19.3.2 Construction operations
500.19.3.2.1 Weather and seasonal limitations - Construction with cold mix must not
undertaken when ambient temperatures below 100C 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 volatile in cool or humid conditions. Wind increases the rate of
evaporation

500.19.3.2.2 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 500.1 and
900.2 as appropriate, and a prime coat if specified in the contract, or required by the
engineer, shall be applied in accordance with clause 500.2, or as directed by the engineer.

500.19.3.2.3 Tack coat - A tack coat in accordance with clause 500.3 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.

500.19.3.2.4 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 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 chosen laying procedure.

500.19.3.2.5 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 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.

500.19.3.2.6 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 25-100 mm and all compaction being in
accordance with clause 500.1.6 and 500.1.7. 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.

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500.19.3.3 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.
500.19.3.4 Surface finish and quality control of work - The surface finish of
construction shall conform to the requirements of clause 900.2. for control of the quality of
materials supplied and the works carried out, the relevant provisions of section 900 shall
apply.

500.19.3.5 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12.

500.19.3.6 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.

500.19.3.7 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 500.1.8.8.2 (i) to (xi). The rate shall cover the provision of the specified grade of
emulsion at the lower quantity in 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.

500.20. SPECIFICATIONS FOR SAND ASPHALT BASE COURSE (U.V-November

2000)
500.20.1 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.

500.20.2 Materials
500.20.2.1 Bitumen - The bitumen shall be paving bitumen of 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.

500.20.2.2 Sand - The sand shall be clean, naturally occurring or blended material fee
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.

500.20.2.3 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 500.7.2.4.

500.20.3 Mix design

500.20.3.1 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 500-42.

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 Table 500-41. Sand grading and physical requirements
Sieve Size Cumulative percentage by weight of total
(mm) 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) 30 min.
Los Angeles Abrasion Value (IS: 2386, Part 4) 40 max.

Table 500-42. Requirements for sand asphalt base course

Parameter requirement
0
Minimum stability (kN at 60 C) 2.0
Minimum flow (mm) 2
Compaction level (Number of blows) 2 x 75
Percent air voids 3-5
Percent voids in mineral aggregate (VMA) > 16
Percent voids filled with bitumen (VFB) 65 - 75

500.20.3.2 Binder content - The binder content shall be optimised to 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.

500.20.3.3 Job mix formula - The contractor shall develop the job mix formula proposed
for use in the works and shall give the following details:
(i) Source and location of all materials;
(ii) 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.

(iii) A single definite 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 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
whom joint samples of all ingredients of the mix shall be furnished by the contractors as
required by the former.

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The approved job mix formula shall remain effective unless and until modified, by the
engineer. Should a change in the source of materials be proposed, a new job mix formula
shall be established and approved by the engineer before actually using the materials.

500.20.3.4 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.

500.20.4 Construction operations

500.20.4.1 Weather and seasonal limitations - Clause 500.1.5.1 shall apply.

500.20.4.2 Preparation of base - The surface on which Sand Asphalt base course
material is to be laid shall be prepared, shaped and graded to the profile required for the
particular layer in accordance with clauses 500.1 and 900.2 as appropriate or as directed
by the engineer. The surface shall be thoroughly swept clean free from dust and foreign
matter using a mechanical brush, and the dust blown off by the 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 500.2 or as directed by the engineer.

Table 500-43. Permissible variations from the job mix formula

Description Permissible variation
Aggregate passing 4.75 mm  6%
Aggregate passing 2.36 mm, 1.18 mm, 0.6 mm  5%
Aggregate passing 0.3 mm, 0.15 mm  4%
Aggregate passing 0.075 mm  2%
Binder content  0.3%
0
Mixing temperature  10 C

500.20.4.3 Tack coat - A tack coat over the base shall be applied in accordance with
clause 500.3, or otherwise as directed by the engineer.

500.20.4.4 Preparation and transportation of the mixture - The provisions of clauses

500.1.3 and 500.1.4 shall apply.

500.20.4.5 spreading - The provisions of clauses 500.1.5.2 to 500.1.5.4 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.

500.20.4.6 Rolling - Clause 500.1.6 shall apply. Generally the initial or breakdown rolling
shall 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

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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.

500.20.5 Opening to traffic - Traffic may be allowed after 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 maximum ambient
temperatures are in excess of 350C, great care is needed to ensure that this criterion is
met particularly where slow moving heavy traffic is involved.

500.20.6 surface finish and quality control of work - The surface finish of the
completed construction shall conform to the requirements of clause 900.2.
For control of the quality of materials supplied and the works carried out, the relevant
provisions of section 900 shall apply.

500.20.7 Arrangements for traffic - During the period of construction, arrangement for
traffic shall be made in accordance with the provisions of clause 100.12.
500.20.8 measurement for payment - Sand Asphalt Base course materials shall be
measured as finished work, for the area covered, in cubic metres, metric tonnes, or in
square metres at a specified thickness, as stated in the contract.

500.20.9 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 500.1.8.8.2 (i) to (xi). The rate shall cover the provisions 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.

500.21. SPECIFICATIONS FOR MODIFIED BINDER (U.V-November 2000)

500.21.1 Scope - Modified binders comprise a base binder, to which is added either
natural rubber, crumb rubber or polymer such as Styrene-Butadiene-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.

500.21.2 Materials
500.21.2.1 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 500.21.3.

500.21.2.2 Modifier - The modifier shall be a natural rubber, crumb rubber or any other
polymer which is compatible with the base binder and which allows the properties given in
clause 500.21.3 to be achieved. For further details IRC:SP:53-1999 may be referred to.
The modifier, in the required quantity shall be blended at the refinery or at the site plant
capable of producing modified binder.

500.21.3 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.
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500.21.4 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.

500.21.5 Quality control of materials

500.21.5.1 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 produced on site then
tests shall be carried out daily. If pre-blended modified binder is used tests shall be
carried out weekly.

Table 500-44. Requirements of polymer modified binders (Elastometric thermoplastics

and rubber latex)
Designation Grade and Requirements Method of Test
PMB 120 PMB 70 PMB 40
0
Penetration at 25 C, 0.1mm, 90 t0 150 50 to 89 30 to 49 IS: 1203 – 1978
100g, 5 sec.
Penetration at 40C, 0.1 mm, 35 22 18 IS: 1205 – 1978
200g, 60 sec, Minimum*
0
Softening Point, (R & B), C, 38 48 59 IS: 1205 – 1978
Minimum
0
Fraas Breaking Point, C, -24 -16 -12 IS: 9381 – 1978
Maximum*
0
Ductility at 27 C, cm, Minimum 75 50 50 IS: 1208 – 1978
0
Flash Point, COC, C, Minimum 220 220 220 IS: 1209 – 1978
Elastic Recovery of Half Thread 70 60 50 ASTM
0
in Ductilometer at 15 C, %, (50)** (40)** (30)** D 5976 – 1996
Minimum
Separation, Difference in 4 4 4 ASTM
0
Softening Point, R&B, C, D5976 – 1996
Maximum
Viscosity at 1500C, Poise 1-3 2-6 4-8 IS:1206 - 1978

Test on Thin Film Oven Test Residue, TFOT (IS: 9382 – 1979)
Designation Grade and Requirements Method of Test
PMB 120 PMB 70 PMB 40
0
Penetration at 4 C, 0.1mm, 18 15 12 IS:1203 – 1978
200g, 60sec, Minimum*
Loss in Weight, %, Maximum 1.0 1.0 1.0 IS: 9382 – 1979
0
Increase in Softening Point, C, 7 6 5 IS:1205 – 1978
Maximum
Reduction in Penetration at 35 35 35 IS: 1203 – 1978
0
25 C, %, Maximum
Elastic Recovery of Half Thread 60 40 35 ASTM
0
in Ductilometer at 15 C, %, (35)** (30)** (25)** D5976 - 1996
Minimum
* Relevant to snow bound cold climate areas
** Natural Rubber Modified Bitumen

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Table 500-45. Requirements of polymer modified binders (Plastomeric thermoplastics)
Designation Grade and Requirements Method of Test
PMB 120 PMB 70 PMB 40
0
Penetration at 25 C, 0.1mm, 90 to 150 50 to 89 30 to 49 IS: 1203 – 1978
100g, 5 sec.
Penetration at 40C, 0.1 mm, 35 22 18 IS: 1205 – 1978
200g, 60 sec, Minimum*
0
Softening Point, (R & B), C, 38 48 59 IS: 1205 – 1978
Minimum
0
Fraas Breaking Point, C, -20 -15 -10 IS: 9381 – 1978
Maximum*
0
Ductility at 27 C, cm, Minimum 50 40 30 IS: 1208 – 1978
0
Flash Point, COC, C, Minimum 220 220 220 IS: 1209 – 1978
Elastic Recovery of Half Thread 60 50 40 ASTM
0
in Ductilometer at 15 C, %, D 5976 – 1996
Minimum
Separation, Difference in 3 3 3 ASTM
Softening Point, R&B, 0C, D5976 – 1996
Maximum
0
Viscosity at 150 C, Poise 1-2 2-4 4-8 IS:1206 - 1978

Test on Thin Film Oven Test Residue, TFOT (IS: 9382 – 1979)
Designation Grade and Requirements Method of Test
PMB 120 PMB 70 PMB 40
0
Penetration at 4 C, 0.1mm, 18 15 12 IS:1203 – 1978
200g, 60sec, Minimum*
Loss in Weight, %, Maximum 1.0 1.0 1.0 IS: 9382 – 1979
0
Increase in Softening Point, C, 7 6 5 IS:1205 – 1978
Maximum
Reduction in Penetration at 35 35 35 IS: 1203 – 1978
250C, %, Maximum
Elastic Recovery of Half Thread 45 35 30 ASTM
0
in Ductilometer at 15 C, %, D5976 - 1996
Minimum
* Relevant to snow bound cold climate areas

Table 500-46. Requirements of polymer modified binders (Treated with modified crumb
rubber)
Designation Grade and Requirements Method of Test
PMB 120 PMB 70 PMB 40
0
Penetration at 25 C, 0.1mm, 50 - 70 50 – 60 40 - 60 IS: 1203 – 1978
100g, 5 sec.
0
Softening Point, (R & B), C, 50 55 60 IS: 1205 – 1978
Minimum
Elastic Recovery of Half Thread 40 35 30 ASTM
in Ductilometer at 150C, %, D5976 - 1996
Minimum

Test on Thin Film Oven Test Residue (IS: 9382 – 1979)

Reduction in Penetration at 60 60 60 IS: 1203 - 1978
0
25 C, %, Maximum
Increase in Softening 5 5 5 IS: 1205 – 1978
0
Point,(R&B), C, Maximum
Elastic Recovery of Residue of 25 20 15 ASTM
Half Thread in Ductilometer at D5976 - 1996
150C, %, Minimum
CRMB – Crumb Rubber Modified Bitumen

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500.21.5.2 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 not less than three pairs of samples shall not exceed 50C.

Other pre-blended modified binders shall be stored with appropriate circulation or agitation
facility, according tot he manufacturer’s instructions.

500.21.6 Measurement for payment - Modified binder supplied for the contract shall be
paid for in Tonnes.

500.21.7 Rate - The contract rate for modified binder shall be as per contract agreement.

500.22. SPECIFICATIONS FOR CRACK PREVENTION COURSES (U.V-November

2000)
500.22.1 Scope - This clause covers the provision of Stress Absorbing Membrane (SAM)
AND Stress Absorbing Membrane Interlayer (SAMI) as measures to inhibit the
propagation of cracks. A SAM is an elastomeric bitumen rubber membrane, which is laid
over a cracked road surface, together with a covering of aggregate chips, in order to
extend the life of the pavement before major treatment is carried out. SAM can be laid as
a single coat or a double coat. A SAMI is a layer, which is applied to a cracked pavement
surface but which is followed (within 12 months) by the application of an overlay course. A
SAMI may be a material similar to that used for a SAM. It may alternatively consist of a
bitumen-impregnated geotextile.

500.22.2 Materials
500.22.2.1 Binder - Binder shall be a modified binder complying with the requirements of
clause 500.23, according to the requirements of the contract, except that paving grade
bitumen of 80-100 penetration complying with requirements of IS:73 shall be used in the
case of a bitumen impregnated geotextile.

500.22.2.2 Aggregate - The requirements of clause 500.10.2.2 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 500.10.2.5.

500.22.2.3 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.

500.22.2.4 Geotextile - The use of geotextile as prescribed for Sl.No.7 in Table 500-47
shall conform to the requirements in section 700.

500.22.3 Construction operations

500.22.3.1 Weather and seasonal limitations - Clause 500.1.5.1 shall apply.

500.22.3.2 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 500.1
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.

500.22.3.3 Application of binder - The equipment and general procedures shall all be in
accordance with the Manual for Construction and Supervision of Bituminous Works. The
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application temperature for modified binder shall be 160-1700C. Binder for bitumen
impregnated geotextile shall be applied according to clause 500.2.4. The surface on
which the binder is to be applied shall be dry.

Table 500.47. Quantity of materials required for 10 sq.m of road surface for stress
absorbing membrane.
Sl. No. Type and Width of Crack Specification of Quantity of
SAM to be binder Quantity of chipping
2
applied kg/10m
1. Hair cracks and map Single coat SAM 8 –10 0.10 m3 of 5.6 mm
nd
cracks upto 3mm width or 2 coat of two chips
coat SAM
2. Map cracks or alligator Single coat SAM 10 – 12 0.11 m3 of 5.6 mm
cracks 3mm to 6 mm chips
width
3. Map cracks or alligator Two coat SAM 12 – 14 0.12 m3 of 5.6 m and
st
cracks 6mm to 9mm width 1 coat and 11.2 mm chips in
nd 3
2 coat 8 – 10 1:1 ratio 0.10 of 5.6
mm chips
4. Cracks above 9mm width Two coat SAM
st 3
and cracked area above 1 coat 14 – 16 0.12m of 11.2 mm
50% chips
nd 3
2 coat 8 - 10 0.10 of 5.6 mm chips
5. All types of cracks with Single coat SAM
crack width below 6mm as interlayer 8 - 10 0.10m3 of 5.6mm chips
6. All types of cracks with Single coat SAM
crack width above 6mm as interlayer 10 - 12 0.10m3 of 11.2mm
chips
7. Bitumen Impregnated
Geotextile

Note :
1. Binder quantities for bitumen impregnated geotextile shall be in the range 0.9 to 1.2
litres/m2. Binder quantities outside this range are permitted according to the geotextile
manufacturer’s instructions and subject to the agreement of the engineer.

500.22.3.4 Application of aggregates - The equipment and general procedures shall all
be in accordance with the Manual for Construction and Supervision of Bituminous Works.
Immediately after application of the modified binder, clean, dry aggregate shall be spread
uniformly on the surface.

500.22.3.5 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.

500.22.3.6 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.

500.22.3.7 Geotextile placement - For bitumen impregnated geotextile, the requirements

of clause 700.4.4.5 of the Ministry’s Specification for Road and Bridge Works (third
revision) shall apply.

500.22.4 Opening to traffic - 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.

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500.22.5 surface finish and quality control of work - The surface finish shall conform to
the requirements of clause 900.2.

For control on the quality of materials supplied and the works carried out, the relevant
provisions of section 900 shall apply.

500.22.6 Arrangements for traffic - During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of clause 100.12.

500.22.7 Measurement for payment - Each application of SAM, SAMI or bitumen-

impregnated geotextile shall be measured as finished work, for the area specified, in
square metres.

500.22.8 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 500.1.8.8.2, (i) to (xi).

SECTION 2200
SUB-STRUCTURE

2200 SPECIFICATIONS FOR SUB-STRUCTURE

2200.1 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.

2200.2 Materials - Materials shall conform to section 1000 of these Specifications.

2200.3 General - A method statement for construction indicating the following shall be
submitted by the contractor for approval of the engineer, well in advance of the
commencement of sub-structure:
1) Sources of materials.
2) Design, erection and removal of form work.
3) Production, transportation, laying and curing `of concrete.
4) Personnel employed for execution and supervision.
5) Tests and sampling procedures.
6) Equipment details.
7) 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.

2200.4 SPECIFICATIONS FOR PIERS AND ABUTMENTS

Masonry, form work, concrete and reinforcement for piers and abutments shall conform to
relevant sections of these specifications. In case of concrete piers, the number of

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horizontal construction joints shall be kept minimum. Construction joints shall be avoided
in splash zones unless specifically permitted by the engineer and provided they are
treated in accordance with special provisions. No vertical construction joint shall be
provided. The work shall conform strictly to the drawings or as directed by the engineer.

In case of tall piers and abutments, use of slip form shall be preferred. The design,
erection and raising of slip form 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 specifications and arrangements shall be subject to the prior approval of
the engineer.

The surface of foundation / well cap/ pile cap shall be scrapped with wire brush and all
loose materials removed. In case reinforcing bars projecting from foundations are coated
with cement slurry, the same shall be removed by tapping, hammering or wire brushing.
Care shall be taken to remove all loose materials around reinforcements. Just before
commencing masonry or concrete work, the surface shall be thoroughly wetted.

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 2700.6

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 back fill 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.

2200.5 SPECIFICATIONS FOR PIER CAP AND ABUTMENT CAP

Form work, 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 top surface of
the pedestal on which bearings are to be placed shall also be cast horizontal.

The surface on which elastomeric bearings are to be placed shall be wood float finished to
a level plane which shall not vary more than 1.5 mm from straight edge placed in any
direction across the area. The surface on which other bearings (steel bearings, pot
bearings) are to be placed shall be cast about 25 mm below the bottom level of bearings
and as indicated on the drawings.

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2200.6 SPECIFICATIONS FOR 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 for
abutments or as shown on the drawings.

Form work, 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.

2200.7 Tests and standards of acceptance - The materials shall be tested in

accordance with these specifications and shall meet the prescribed criteria.

The work shall conform to these specifications and shall meet the prescribed standards of
acceptance.

2200.8 Tolerances in concrete elements

a) Variation in cross-sectional dimensions : + 10 mm
- 5 mm
b) Misplacement from specified position in plan : 10 mm
c) Variation the 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

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2200.9 Measurements for payment - 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.
2200.10 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.

SECTION 2900

PIPE CULVERTS

2900 SPECIFICATIONS FOR PIPE CULVERTS

2900.1 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.

2900.2 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.

2900.3. 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

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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 back filled with approved granular
material which shall be properly shaped and thoroughly compacted up to the specified
level.

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

Trenches shall be kept free from water until the pipes are installed and the joints have
hardened.

2900.4 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 one of the following two types as specified on the drawings:

1) 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 atleast ten per cent of its overall height or as
otherwise shown on the drawings. The bedding material shall be well graded sand or
another granular material passing 5.6 mm sieve suitably compacted/rammed. The
compacted thickness of the bedding layer shall be as shown on the drawings and in no
case shall it be less than 75 mm.

2) Concrete cradle bedding - When indicated on the drawings or directed by the

engineer, the pipe shall be bedded in a cradle constructed of concrete having a mix not
leaner than M 15 conforming to section 1700. The shape and dimensions of the cradle
shall be as indicated on the drawings. The pipes shall be laid on the concrete bedding
before the concrete has set.

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2900.5 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 atleast 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 upstream. The pipes shall be fitted and
matched so that when laid in work, they form a culvert with a smooth uniform invert.

Any pipe found defective or damaged during laying shall be removed at the cost of the
contractor.

2900.6 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 mm
according to the diameter of the pipe. Caulking material shall be slightly wet mix of cement
and sand in the ratio of 1:2 rammed with caulking irons. Before caulking, the collar shall
be so placed that its centre coincides with the joint and an even annular space is left
between the collar and the pipe.

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 when forced with a trowel or rammer. Care shall be
taken to fill and 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.

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2900.7 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.
Backfilling up to 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 launches of the pipe.
Approved pneumatic or light mechanical tamping equipment can be used.

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 up to 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.

2900.8 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.
2900.9 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 at least 600 mm.

2900.10 Measurements for payment - R.C.C. pipe culverts shall be measured along
their centre between the inlet and outlet ends in linear metres.

Selected granular material and cement concrete for pipe bedding shall be measured as
laid in cubic metres. Ancillary works like headwalls, etc., shall be measured as provided
for under the respective Sections.

2900.11 Rate - The contract unit rate for the pipes shall include the cost of pipes including
loading, unloading, hauling, 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.

SECTION 1400
STONE MASONRY

1400. SPECIFICATIONS FOR STONE MASONRY

1400.1 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.

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1400.2. Materials - All materials used in stone masonry shall confirm to section 1000
except cement mortar for stone masonry, which shall conform to clause 1300.4.

1400.3 Personnel - Only trained personnel shall be employed for construction and
supervision.

1400.4. 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.

1400.5 Construction operations

1400.5.1 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 (Annexure 1400-A.1) and requirement for dressing of stone covered in
IS: 1129(Annexure 1400-A.2). Other specific requirements are covered separately
with respect to particular types of rubble stone work.

1400.5.2 Laying
1400.5.2.1 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.

1400.5.2.2. Stones shall be sufficiently wetted before laying to prevent absorption of water
from mortar.

Stratified stones must be laid on their natural beds. All bed joints shall be normal to the
pressure upon them.

Stones in the hearting shall be laid on their broadest face that gives a better opportunity to
fill the spaces between stones.

The courses of the masonry shall ordinarily be pre-determined. They shall generally be of
the same height. When there is to be variation in the height of the 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

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then poured in the joints. No dry or hollow space shall be left anywhere in the masonry
and each stone shall have all the embedded faces completely covered with mortar.

In tapered walls, the beds of the stones and the planes of course should be at right angles
to the batter. In case of bridge piers with batter on both sides, the course shall be
horizontal.

The bed which is to receive the stone shall be cleaned, wetted and covered with a layer of
fresh mortar. All stones shall be laid full in mortar both in bed and vertical joints and
settled carefully in place with a wooden mallet immediately on placement and solidly
embedded in mortar before it has 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 work over rock, a
leveling 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 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 top of another, freshly laid.

Shaping and dressing shall be done before the stone is laid in the work. No dressing and
hammering, which will loosen the masonry, will be allowed after it is once placed. All
necessary chases for joggles, dowels and clamps should be formed before hand.

Sufficient transverse bonds shall be provided by the use of bond stone extending from the
front to the back of the wall and in case of thick wall from outside to the interior and vice
versa. In the latter case, bond stones shall overlap each other in their arrangement.

In case headers are not available, precast headers of M 15 concrete shall be used. Cast-
in-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 throughout.

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In bond work at all angle junctions of walls, the stones at each alternate course shall be
carried out 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 alternatively 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.

1400.5.3. Random masonry (uncoursed and coursed)

1400.5.3.1. Dressing - Stones shall be hammer dressed on the face, the sides and beds
to enable it to come in proximity with the neighboring stone. The bushing on the exposed
face shall not be more than 40 mm.

1400.5.3.2. 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 up to 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.

1400.5.3.3. 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 hearing should be
laid nearly level with facing and backing.

1400.5.3.4. Bond stones - Through bond stones shall be provided in masonry up to 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 sandstone's,
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

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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.

1400.5.3.5. 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.

1400.5.3.6. 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.

1400.5.3.7. 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 the
adjacent stone so as to form neat 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.

1400.5.3.8. 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.

1400.5.4. Square rubble- coursed rubble (first sort)

1400.5.4.1. 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.

1400.5.4.2. 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.

1400.5.4.3. 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.

1400.5.4.4. 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 450 mm 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.

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1400.5.4.5. Face stones - Face stones shall tail into the work for not less than their
heights and at least one-third of the stones shall tail into the work for a length not less than
twice their height . These shall be laid as headers and stretchers alternately.

1400.5.4.6. Laying - The stones shall be laid on horizontal courses and all vertical joints
should be truly vertical. The quoin stone should be laid header and stretcher alternately
and shall be laid square on their beds, which shall be rough chisel dressed to a depth of at
least 100mm.

1400.5.4.7 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.

1400.5.5 Ashlar masonry (plain ashlar) :

1400.5.5.1. Dressing - Every stone shall be cut to the required size and shape, chisel
dressed on all beds and joints so as to be 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 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.

1400.5.5.2. Bond stones - Through bond stones shall be provided in masonry up to 600
mm thickness and in case of masonry above 600 mm thickness, a set of two 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 sand stones,
etc.,) the bond stone shall extend only about two-third into 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.

1400.5.5.3. 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.

1400.5.5.4 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 20mm depth from
face shall be left with the help of a stone plate during the progress of work.

1400.5.6. Pointing - Pointing shall be carried out using mortar mot leaner than 1:3 by
volume of cement and sand or as shown on the drawing. The mortar shall be filled and
pressed into the raked out joints before giving the required finish. The pointing shall
conform to clause 1300.12.3 of the specification. The work shall conform to IS: 2212

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(Annexure 1300.A-1). The thickness of joints shall not be less than 3 mm for Ashlar
masonry. However, the maximum thickness of joints in different works shall be as follows
:

Random Rubble : 20 mm
Coursed Rubble : 15 mm
Ashlar Masonry : 5 mm

1400.5.7. Curing - Curing shall conform to clauses 1300.9 and 1300.12.5.

1405.8. Scaffolding - For scaffolding clause 1300.10 shall apply.

1405.9. Weep holes - Weep holes shall conform to clause 2700.6.

1400.5.10. Jointing with existing structures - For jointing with existing structures, the
specifications given under clause 1300.8 shall apply.

1400.6. Architectural coping for wings/return/parapet walls - Architectural coping for

wing/return/parapet walls shall conform to clause 1300.13.

1400.7. Tests and standard of acceptance - All work shall be done to the lines and
levels as indicated on the drawing or as directed by the engineer subject to tolerances as
specified in the specifications.

Mortar cubes shall be taken in accordance with IS: 2250 (Annexure 1300-A.2) 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.

1400.8. Measurements for payment - Stone masonry shall be measured in cubic metres.
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.

1400.9. 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 directed 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,

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cleaning, wetting, filling with mortar, trowelling, pointing and watering, sampling and
testing and supervision as directed in these specifications.

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.

---- oo0oo ----

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