NAME OF WORK:- CONSTRUCTION OF CANAL

STRUCTURE ON BARDOLI-MOTA-MIRAPUR -ORNA

ROAD ( NEAR UMRAKH CANAL STRUCTURE ) K.M.
0/100 TO 10/430 ( W/S CH. 2/600 TO 2/800). TA.
BARDOLI, DI. SURAT.

TECHNICAL SPECIFICATIONS

For Schedule B

1
 TECHNICAL SPECIFICATIONS
1.0 PREAMBLE:-
1.1 The Technical Specifications contained herein shall be read in conjunction with the other
Bidding Documents as specified in this Volume.
1.2 Site Information:-
1.2.1 The information given here under provided elsewhere is given in good faith by the
Employer but the Contractor shall satisfy himself regarding all aspects of site conditions and no
claim will be entertained on the plea that the information supplied by the Employer is erroneous
or insufficient.
2.0 GENERAL REQUIREMENTS:-
The technical specifications in accordance with which the entire work described herein after
shall be constructed and completed by the Contractor shall comprise of the "SPECIFICAITON"
2.1 The "SPECIFICATION" for each item is attached with tender is based on following.
(1) "SPECIFICATION FOR ROAD AND BRIDGE WORKS' (Fifth Revision printed in year 2013)
issued by the Ministry of Road Transport & Highways (MORT & H), Government of India and
Published by the Indian Roads Congress, hereinafter to as MORT & H Specifications.
(2) The General Technical Specifications for Road works.
(3) The General Technical Specifications for Bridge works.
Note:- (2) To (3) are Conventional Specifications Booklets usually attached for (R&B) Works.
2.2 If, a particular clause (which is incorporated in "SPECIFICATION") of specification booklets
(1) to (3) above is Amended / Modified/ Added upon then the Amendment/
Modification/Addition shall supersede the relevant clause incorporated in " SPECIFICATION"
2.3 In, so far as Amended / Modified / Added Clause may come in conflict or be inconsistent
with any of the provisions of the MORT & H Specifications under reference, the
Amended/Modified/ Added Clause and the additional specifications shall always prevail.
2.4 In the absence of any definite provisions on any particular issue in the aforesaid
Specifications, reference may be made to the latest codes and specification, of IRC and BIS in
that order. Where even these are silent, the construction and completion of the works shall
conform to sound engineering practice as approved by the ' Engineer' and , in case of any
dispute arising out of the interpretation of the above, the decision of the 'Engineer' shall be final
and binding on the Contractor.

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NAME OF WORK: CONSTRUCTION OF CANAL STRUCTURE ON
BARDOLI-MOTA-MIRAPUR -ORNA ROAD ( NEAR UMRAKH CANAL
STRUCTURE ) K.M. 0/100 TO 10/430 ( W/S CH. 2/600 TO 2/800).
TA. BARDOLI, DI. SURAT.

ITEM WISE SPECIFICATION

Item No.:- 1 Dismantling the existing structure including removing
and stacking the dismantle led material for all lead as directed. by
Engineer-in-Charge.
1. This work shall consist of removing , as here in after set forth, existing
culverts, bridges, pavements, kerbs and other structures like guard-rails,
fences, utility poles, manholes, catch basins, inlets, etc. Which are in place but
interfere with the new construction or are not suitable to remain in place, and
of salvaging and disposing of the resulting materials and backfilling the resulting
trenches and pits.
2 Existing culverts, bridges, pavements -and other structures which are
within the highway and which are designed to be removed shall be removed
upto the limits and extent specified in the drawings or as indicated by the
Engineer-in-charge.
3. Dismantaling and removal operations shall be carried out with equipment
and in such a manner as to leave undisturbed, adjacent pavement, structure
and any other work to be left in place.
4. 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.
5. The structures shall be dismantaled 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.
6. Unless otherwise specified, the superstructure portion of culverts/
bridges shall be entirely removed and other parts removed to below the ground
level or as necessary depending upon the interference they cause to the new
construction. Removal of overlying or adjacent materials if required in
connection with the dismantaling of the structures, shall be incidental to this
item.
7. Where existing culverts/ bridges are to be extended or otherwise
incorporated in the new work, only such part of the existing structure shall be
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removed as are necessary 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.
Reinforcing bars which are to be left in place so as to project into new work as
dowels or ties shall not be injured during removal of concrete.
8. Pipe culverts shall be carefully removed in such a manner t6 avoid
damage to the pipes.
9. Steel structures shall unless otherwise provided be carefully dismantled
in such a manner as to avoid damage to members thereof. If specified in the
drawing or directed by the Engineer-in-charge that structure is to be removed
in a condition suitable for re-erecting, 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 surface shall be painted with a mixture of white lead
and tallow and all loose parts shall be securely wired to adjaced members or
packed in boxes.
10. Timber structures shall be removed in such a manner as to avoid damage
to such timber or lumber as is designated to be salvaged by the Engineer-in-
charge.
11. 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 out and chipped to a true line with a face perpendicular to
the surface of the existing strata. Sufficient removal shall be made to provide
for proper grades and connections with the new work as directed by the
Engineer-in-charge.
12. All concrete pavements, base course in carriage way and shoulders etc.
designed for removal shall be broken to pieces whose volume shall not exceed
0.02 cubic metre and stockpiled at designated iodations if the materials is to be
used later or otherwise arranged for disposal as directed.
13. Where directed by the Engineer-in-charge holes and depressions caused
by dismantling operations shall be backfilled with excavated or other approved
materials thoroughly compacted in line with surrounding area.
14. 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 material with the right of way as directed
by the Engineer-in-charge, for which Contractor will remain responsible for its
safe custody and preservation for 60 days after recording measurements of the
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 salvaged materials. Pipe culverts that are removed shall be cleared and nearly
piled on the right-of-way at point designed by the Engineer-in-charge.
15. Pipe culverts that are removed shall be cleared and neatly piled on the
right of way at points designated by the Engineer-in-charge.
16. Structural steel removal from old structure shall, unless otherwise
specified or directed, be stored in a neat and presentable manner. Structures
or portions thereof which are specified in the contract for re-erections shall be
stored in separate piles.
17. Timber or lumber from old structure which is designated by the Engineer-
in-charge as materials to be shall have all rails and bolts removed there from
and shall be stored in neat piles locations suitable for loading.
18. All the products of dismantling operations which in the opinion of the
Engineer-in-charge cannot be used or auctioned shall, be disposed as directed,
within 100 metres.,
19. The work of dismantling structures shall be paid for in units indicated
below by taking measurements before and after, as applicable.
(i) Dismantling Stone/brick/concrete (Plain and Reinforced) masonry Cubic Meter
(ii) Dismantling flexible and cement concrete pavement./RCC pipes Cubic Meter
(iii) Dismantling steel structure. Tonne
(iv) Dismantling timber structure Cubic Meter
(v) Dismantling pipes, guard rails, kerbs, gutters and fencing. Linear Meter
(vi) Utility poles. Nos.
20. The contract unit rates for the various items of dismantling shall by
payment 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 and for handling, salvaging, piling and
disposing of the dismantled materials within all lifts and upto a lead of 100
metres.
The rate shall be for unit of one Cubic meter basis for completed item as
directed.

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Item No.2: - Excavation for foundation in sand , gravel , clay soft soils
& murrum etc. including sorting and strutting and dewatering as
necessary and disposing of excavated stuff as directed. With all lead
& lift.
304.1. Scope
Excavation for structures shall consist of the removal of material for the
construction of foundations for bridges, culverts, retaining walls, headwalls,
cutoff 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, work shall include construction
of the necessary cofferdams and cribs their subsequent removal; all necessary
sheeting, shoring, bracing, and pumping; the removal of all logs, stumps, grubs
and other matter and obstructions, necessary for placing the foundations;
trimming bottoms of excavations; backfilling and clearing up the site the
disposal of all surplus material.

304.2. Classification of Excavation

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 murrum, a mixture of these and similar material which
yields 10 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.

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.

304.3. Construction Operations

304.3.1. Setting out: After the site has been cleared according to Clause 201,
the limits of excavation shall be set out true to lines, curves and slopes to Clause
301.3.1.

304.3.2. Excavation: Excavation shall be taken to the width of die lowest

step of the footing and the sides shall be left plumb where the nature of soil
allows it. Where the nature of soil or the depth of the trench and season of
the year do not permit vertical sides, the Contractor at his own expense shall
put up necessary shoring, strutting and planking or cut slopes to a safer angle
or both with due regard to the safety of personnel and works and to the
satisfaction of the Engineer.
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The depth to which the excavation is to be carried out shall be as shown on the
drawings, unless the type of material encountered is such as to require
changes, in which case the depth shall be as ordered by the Engineer. Propping
shall be undertaken when any foundation or stressed zone from an adjoining
structure is within a line of 1 vertical to 2 horizontal from the bottom of the
excavation.
Where blasting is to be resorted to, the same shall be carried out in accordance
with Clause 302 and all precautions indicated therein observed. Where blasting
is likely to endanger adjoining foundations or other structures, necessary
precautions such as controlled blasting, providing rubber mat cover to prevent
flying of debris etc. shall be taken to prevent any damage.

304.3.3. Dewatering and protection: Normally, open foundations shall be

laid dry. Where water is met with in excavation due to stream flow, seepage,
springs, rain or other reasons, the Contractor shall take adequate measures
such as bailing, pumping, constructing diversion channels, drainage channels,
bunds, depression of water level by well-point system, cofferdams and other
necessary works to keep the foundation trenches dry when so required and
to protect the green concrete/masonry against damage by erosion or sudden
rising of water level. The methods to be adopted in this regard and other
details thereof shall be left to the choice of the Contractor but subject to
approval of the Engineer. Approval of the Engineer shall, however, not relieve
the Contractor of the responsibility for the adequacy of dewatering and
protection arrangements and for the quality and safety of the works.

Where cofferdams are required, these shall be carried to adequate depths and
heights, be safely designed and constructed and be made as watertight as is
necessary for facilitating construction to be carried out inside them. The interior
dimensions of the cofferdams shall be such as to give sufficient clearance for
the construction and inspection and to permit installation of pumping
equipment’s, etc., inside the enclosed area.

If it is determined beforehand that the foundations cannot be laid dry or the

situation is found that the percolation is too heavy for keeping the foundation
dry, the foundation concrete shall be laid under water by tremie pipe only. In
case of flowing water or artesian springs, the flow shall be stopped or reduced
as far as possible at the time of placing the concrete.

Pumping from the interior of any foundation enclosure shall be done in such a
manner as to preclude the possibility of the movement of water through any
fresh concrete. No pumping shall be permitted during the placing of concrete
or for any period of at least 24 hours thereafter, unless it is done from a suitable
sump separated from the concrete work by a watertight wall or other similar
means.

At the discretion of the Contractor, cement grouting or other approved methods

may be used to prevent or reduce seepage and to protect the excavation area.
7
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.

304.3.4. Preparation of foundation: The bottom of the foundation shall be

levelled both longitudinally and transversely or stepped as directed by the
Engineer. Before footing is laid, the surface shall be slightly watered and
rammed. In the event of excavation having been deeper than that shown on
the drawings or as otherwise ordered the Engineer, the extra depth shall be
made up with concrete masonry of the foundation at the cost of the Contractor
as per Clause 2104.1. Ordinary filling shall not be used for the purpose to bring
the foundation to level.
When rock or other hard strata is encountered, it shall be freed of all soft and
loose material, cleaned and cut to a firm surface either level and stepped as
directed by the Engineer. All seams shall be denied out and filled with cement
mortar or grout to the satisfaction of die Engineer. In the case of excavation in
rock, annular space around footing shall be filled with lean concrete M15 upto
the top level of rock.

If the depth of fill required is more than 1.5m above the top of the footing,
filling upto 1.5m above top of footing shall be done with lean concrete M15
followed by boulders grouted with cement.

When foundation piles are used, the excavation of each pit shall be substantially
completed before beginning pile-driving operations therein. After pile driving
operations in a given pit are completed, all loose and displaced materials therein
shall be removed to the elevation of the bottom of the footings.

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

304.3.6. Public safety: Near towns, villages arid all frequented places,
trenches and foundation pits shall be securely fenced, provided with
proper caution signs and marked with red lights at night to avoid accidents.
The Contractor shall take adequate protective measures to see that the
excavation operations do not affect or damage adjoining structures. For safety
precautions, guidance may be taken from IS: 3764.

304.3.7. Backfilling: Backfilling shall be done with approved material after

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

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304.3.8. Disposal of surplus excavated materials: All the excavated
materials shall either be reused with the approval of the Engineer or disposed
off with all leads and lights as directed by the Engineer. Rates quoted by the
Contractor deemed to include credit for usable material and salvage value of
unusable 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 and no extra payment shall be made for the
same.
All hard materials, such as, hard murrum, rubble, etc., not intended for
use as above shall be stacked neatly on specified land as directed by the
Engineer with all lifts
Unsuitable and surplus material not intended for use within the lead
specified above shall also, if necessary, be transported with all lifts and lead
and disposed of or used as directed by the Engineer.

304.4. Measurements for Payment

Excavation for structures shall be measured in cubic meter 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,
production/support to the existing structures shoring, shuttering and planking
shall be deemed as convenience for the Contractor in executing the work and
shall not be measured and paid separately.

Foundation sealing, dewatering, including pumping shall be deemed to be

incidental to the work unless separate provision is made for in the Contract.

304.5. Rates

304.5.1. The Contract unit rate for the items of excavation for structures shall
be payment in full for carrying out the required operations including full
compensation for:

(i) Setting out;

(ii) Construction of necessary cofferdams, cribs, sheeting, shoring and
bracing and their subsequent removal;
(iii) Removal of all logs, stumps, grubs and other deleterious matter and
obstructions, for placing the foundations including trimming of bottoms
of excavations;
(iv) Foundation sealing, dewatering including pumping when no separate
provision for it is made in the Contract;
(v) Backfilling, clearing up the site and disposal of all surplus material within
all lifts and leads or as otherwise specified; and
(vi) All labour, materials, tools, equipment, safety measures, diversion of
traffic and incidentals necessary to complete the work to Specification.
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304.5.2. The Contract unit rate for preparation of rock foundation shall be full
compensation for cutting, trimming and cleaning the foundation surface and
filling/sealing of all seams with cement grout or mortar including all materials,
labour and incidentals required for completing the work.

Item No.3: - Providing & filling in foundation as base course with

ordinary cement concrete of M 10 mix and providing necessary
vertical pin headers including formwork vibrating ramming & curing
complete.

Ordinary cement concrete of specified Grade shall be carried out in accordance

with the following specification.

1. In case of ordinary concrete, mix is not required to be designed by

preliminary tests and proportions of cement, fine aggregates and coarse
aggregates are specified by volume as given in table below for different grades
of concrete designated as ordinary M. 10, M. 15, M.20 and M.25.

2. In the designation of a concrete mix, letter "M" refers to the mix and the
number the specified 28 days works cube compressive strength of that mix on
150 mm. cubes expressed in kg/cm2.
3. The ordinary concrete mix shall generally be specified by volume. For
cement which normally comes in bags and is used by weight, volume shall be
worked out taking 50 kg. of cement as 0.035 cubic meter in volume. While
measuring aggregate by volume, shaking, ramming or hammering shall not be
done. Proportioning of sand shall be as per its dry volume. In case it is dump,
allowance for "bulking" shall be made as per IS : 2386 (Part-III).

4. Ingredients required for ordinary concrete containing one 50 Kg. bag of

cement of different proportions of mix shall be as given in Table below.
TABLE
Grade of Mix By Total Quantity of dry Proportion of fine Quantit
Concrete Volume aggregates by volume aggregate to coarse y of
per 50 Kg. of cement, to aggregate water
be taken as sum of the per 50
individual volumes of kg. of
fine and coarse cement
aggregates max max.
1 2 3 4 5
(1 Cubic meter = 1000 liters)
Ordinary Liters Liters
M.100 1:3:6 300 General 1:2 for fine 34
aggregate to coarse
M.150 1:2:4 220 aggregate by 32
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 volume but subject
M.200 1:1.1/2 160 to a upper limit of 30
:3 1:1. ½ & a lower
M.250 1:1:2 100 limit of 1:3 27

NOTE- The proportions of the aggregates shall be adjusted from upper

limit to lower limit progressively as the grading of the fine aggregates becomes
finer & the maximum size of coarse aggregate becomes larger.

Example- For an average grading of fine aggregate (that is Zone II of IS :

383-1963) the proportions shall be 1: 11/2, 1:2 and 1:3 for maximum size of
aggregates 10 mm, 20 mm. and 40 mm. respectively (after carrying out sieve
analysis).

Note-2 A mix leaner than M.100 (1:3:6) may be used for non- structural
parts, if provided in the contract. In such case grading of aggregates shall be
by volume. Other requirements for mixing, placing & curing shall be the same.

5. Following shall be the maximum nominal size of coarse aggregate for

the different items of work:
Sr. Item of Construction Maximum nominal size
No. of Coarse aggregate
(i) R.C.C. well curb and R.C.C. Piles 40 mm
(ii) R.C.C. well staining 63 mm
(iii) Well cap or pile cap; solid type piers, 40 mm
abutment and wing-walls, and their pier
caps
(iv) R.C.C. works in cross girders deck slab, 20 mm
wearing coats, kerb, light posts, blast
walls, approach slab etc. and hollow type
piers, abutments, wing-walls and their pier
caps
(v) R.C.C. bearings. 20 mm.
(vi) For any other item of construction not As specified on the
covered by items (i) to (v) drawing or as desired
by the Engineer-In-
charge in case it is not
specified on drawing.

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 For heavily reinforced concrete members as in the case of ribs of main
beams nominal maximum size of aggregate shall usually be restricted to 5 mm.
less than the minimum lateral clear distance between the main bars or 5 mm.
less than the minimum cover to the reinforcement, whichever is the smaller.

6. Fine aggregate shall be clean, hard, coarse sand. It shall be free from
dust and such other substances. The sand be got approved by the Engineer-
in-charge.

7. All materials shall be stored as to prevent their deterioration or intrusion

of their quality and fitness for the work. Any material which has deteriorated or
has been damaged or is otherwise considered defective by the Engineer-in-
charge shall not be used in the works.

8. Cement shall be stored above the ground level in perfectly dry and water
tight sheds. Wherever bulk storage containers are used, their capacity should
be sufficient to cater to the requirements at site and should be cleaned at least
once every 3 to 4 months. The aggregate shall be stored in such a way as to
prevent admixture of foreign materials. Different size of fine or coarse
aggregate shall be stored in separate stock-piles sufficiently away from the
each other to prevent intermixing the materials.

9. The water for mixing shall be potable water to satisfaction of the

Engineer-in-charge. The quantity of water shall be just sufficient to produce a
dense concrete of required workability for the job.

10. For all work concrete shall be mixed in a mechanical mixer which along
with other accessories shall be kept in first class working condition and so
maintained throughout the construction. Mixing shall be continued till materials
are uniformly distributed and uniform colour of the entire mass is obtained and
each individual particle of the coarse aggregate show complete coating of
mortar containing its proportionate amount of cement. In no case shall the
mixing be done for less than 2 minutes after all ingredients have been put into
the mixer.

11. When hand mixing is permitted by the Engineer-in-charge for small jobs
or for certain other reasons. It shall be done on a smooth watertight platform
large enough to allow efficient turning over of the ingredients of concrete
before and after adding water. Mixing platform shall be so arranged that no
foreign material shall get mixed with concrete nor does the mixing water flow
out. Cement in required number of bags shall be placed in a uniform layer on
top of the measured quantity of fine and coarse aggregate, which shall also be
spread in a layer of uniform thickness on the mixing platform. Dry coarse and
fine aggregate and cement shall then be mixed thoroughly by turning over to
get a mixture of uniform colour. Enough water shall then be added gradually
through a rose can and the mass turned over till a mix of required consistency

12
is obtained. In hand mixing quantity of cement shall be increased by 10 per
cent above that specified.

12. Mixers which have been-out of use for more than 30 minutes shall be
thoroughly cleaned before putting in a new batch. Unless otherwise agreed to
be the Engineer-in-charge, the first batch of concrete from the mixer shall
contain only two thirds of normal quantity of coarse aggregate. Mixing plant
shall be thoroughly cleaned before changing from one type of cement to
another.

13. The method of transporting and placing concrete shall be approved by

the Engineering-in-charge. Concrete shall be so transported and placed that no
contamination, segregation or loss of its constituent material takes places. All
form work and reinforcement contained in it shall be cleaned and made free
from standing water, dust, snow or ice immediately before placing of concrete.
No concrete shall be placed in any part of the structure until the approval of
the Engineer-in-charge has been obtained.

14. If concreting is not started within 24 hours of the approval being given,
it shall have to be obtained again from the Engineer-in-charge. Concreting
being given, it shall proceed continuously over the area between construction
joints. Fresh concrete shall not be placed against concrete which has been in
position for more than 30 minutes unless a proper construction joint is formed.
Concrete shall be compacted in its final position within 30 minutes of its
discharge from the mixer unless carried in properly design agitators, operating
continuously, when this time shall be within 2 hours of the addition of cement
to the mix and within 30 minutes of its discharge from the agitator. Except
where otherwise agreed to be the Engineer-in-charge, concrete snail be
deposited in horizontal layers to a compacted depth of nor more than 0.45
meter when internal vibrators are used and not exceeding 0.30 meter in all
other cases.

15. Unless otherwise agreed to by the Engineer-in-charge concrete shall not

be dropped into place from a height exceeding 1.2 meters. When trucking or
chutes are used they shall be kept clean and used in such a way as to avoid
segregation. When concreting has to be resumed on a surface which has
hardened, it shall be roughened, swept, clean, thoroughly wetted and covered
with a 13 mm. thick layer of mortar composed of cement and sand in the same
ratio as in the concrete mix itself. This 13 mm. layer of mortar shall be freshly
mixed and placed immediately before placing of new concrete. Where concrete
has not fully hardened, all laitance shall be removed by scrubbing the well
surface with wire or bristle brushes, care being taken to avoid dislodgement of
any particles of coarse aggregate. The surface shall then be thoroughly wetted,
all free water removed and then coated with neat cement grout. The first layer
of concrete to be placed on this surface shall not exceed 150 mm. in thickness,
and shall be well rammed against old work particular attention being given to
corners and close spots.
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16. All concrete shall be compacted to produce a dense homogeneous mass
with the assistance of vibrators, unless otherwise permitted by the Engineer-
in-charge for exceptional cases, such as concreting under water, where
vibrators cannot be used. Sufficient vibrators in serviceable condition shall be
kept at site so that spare equipment is always available in the event of break
downs.

17. Immediately after compaction, concrete shall be protected against

harmful effects of weather, including rain, running water, shocks, vibration,
traffic, rapid temperature changes, frost and driving out process. It shall be
covered with wet sacking, hessian or other similar absorbent material approved
by the Engineer-in-charge soon after the initial set, and shall be kept
continuously wet for a period of not less than 14 days from the date of
placement. Masonary work over the foundation concrete may be started after
48 hours of its laying but the curing of concrete shall be continued for a
minimum period of 14 days.

18. From work shall include all temporary or permanent forms required for
forming the concrete, together with all temporary construction required for
their support. Form work shall however be divided into following two distinct
categories:-
(1) Shuttering i.e., form work required for forming the concrete.
(2) Scaffolding i.e., form-work required for supporting shuttering.
Forms for shuttering shall be constructed only in metal suitably lined. Forms for
scaffolding shall be constructed of metal or timber. Both shuttering and
scaffolding shall be or substantial-rigid construction and shuttering shall be true
to shape and dimensions shown on the drawings. All bolts and rivets shall be
counter-sunk and well ground to provide a smooth, plane surface.

19. Forms shall be mortar-tight and shall be made sufficiently rigid by the
use of ties and bracings to prevent any displacement or sagging between
supports, They shall be strong enough to withstand all pressure, ramming and
vibration, without deflection from the prescribe lines occurring during and after
placing the concrete. Screw jacks or hard wood wedges where required shall
be provided to make up any settlement in the formwork either before or during
the placing of concrete. Suitable comber shall be provided in horizontal
members of structure, specially in long spans to counteract the effects of any
fixed as to provide for such camber. Forms shall be so constructed as to be
removable in sections in the desired sequence, without damaging the surface
of concrete or disturbing other sections. Unless otherwise specified or directed,
chambers or fillets of sizes 25 mm x 25 mm shall be provided at all angles of
formwork to avoid sharp corners.

20. The inside surfaces of shuttering shall, except in the case of permanent
form work or where otherwise agreed to by the Engineer-in- charge, be coated
with an approved material to prevent adhesion of concrete to the form work.
Release agents shall be applied strictly in accordance with the manufacturer's
14
instructions and shall not be allowed to come into contact with any
reinforcement or pre-stressing tendons and anchorages. Different release
agents shall not be used in form work for concrete which will be visible in the
finished works.

21. Special measures shall be taken to ensure that the form work does not
hinder the shrinkage of concrete because without these cracking could occur
before the from work is removed. Where ever applicable arrangements must
be made to ensure that the form work does not restrain the shortening and
hogging of the beams or slabs during tensioning of the tendon's. The form work
should take due account of the calculated amount of positive or negative
camber so as to ensure the correct final shape of the structures having regard
to me deformation of a false work, scaffolding or propping and the
instantaneous or deferred deformation due to various causes affecting pre-
stressed structures. Where there are re-entrant angles in the concrete sections
the form work should be removed, at those sections as soon as possible after
the concrete has set in order to avoid cracking due to shrinkage 0f concrete.
From work shall be tight enough to prevent any appreciable loss of cement
during vibrations, suitable tolerances should be provided in the harm work.
Immediately before concreting all forms shall be thoroughly cleaned. Contractor
shall give the Engineer-in-charge due notice before pairing any concrete in the
forms to permit him to inspect and accept the false work and forms as to their
strength alignment and general fitness, but such inspection .shall not relieve
the contractor of his responsibility for safety of men, machinery, materials and
for results obtained.

22. The Engineer- in-charge shall be informed in advance by the contractor

of his intention to strike any formwork. While fixing the time for removal of
formwork, due consideration shall be given to local conditions, character of the
structure, the weather and other conditions that influence the setting of
concrete and of the materials used in the mix. Where field operations are
controlled by strength tests of concrete, the removal of the load-supporting or
soffit forms may commence when concrete has attained strength equal to at
least twice the stress to which the concrete will be subjected at the time of
striking props including the effect of any further addition of loads. When field
operations are not controlled by strength tests of concrete the vertical forms of
beams, columns and walls may be removed after 2 days. The props of slabs
and beams may be removed after 14 and 21 days respectively. All formwork
shall be removed without causing any damage to the concrete. Centering shall
be gradually and uniformly lowered in such a manner as to permit the concrete
to take stresses due to its own weight uniformly and gradually. Where internal
metal ties are permitted, they or their removable parts shall be extracted
without causing any damage to the concrete and remaining holes filled with
mortar No permanently embedded metal part shall have less than 25 mm. cover
to the finished concrete surface. Where it is intended to refuse the formwork,
it shall be cleaned and made good to the satisfaction, of the Engineer-in-charge.

15
23. Immediately after the removal of forms, all exposed bars or bolts passing
through the Cement concrete member and used for shuttering or any other
purpose shall be cut inside the cement concrete member to a depth of at least
25 mm. below the surface of the concrete and the resulting holes be filled by
cement mortar. All fins caused by form joints, all cavities produced by the
removal of form ties and all other holes and depressions, honey comb spots,
broken edges or corners and other defects, shall be thoroughly cleaned,
saturated with water and carefully pointed and rendered true with mortar of
cement and fine aggregate mixed in the proportions used in the grade of
concrete that is being finished and of as dry as consistency as is possible to
use. Considerable pressure shall be applied in filling and pointing to ensure
thorough filling in all voids. Surfaces which have been pointed shall be kept
moist for a period of twenty four hours. If rock pockets/honeycombs, in the
opinion of the Engineer-in-charge are of such an extent or character as to affect
the strength of the structure materially or to endanger the life of the steel
reinforcement, he nay declare the concrete defective and require the removal
and replacement of the portions of the structure affected.

24. In the case of reinforced concrete work workability shall be such that the
concrete surrounds and properly grips all reinforcement. The degree of
consistency, which shall depend upon the nature of work and methods of
vibration of concrete shall be determined by regular slump tests. Following
slump shall be adopted for different types of works.

Slumps
Where Where
Type of Work vibrators are vibrators are
used not used

1 Mass concrete in RCC foundations, 10 mm to 80 mm

1 footings and retaining walls 25 mm
2 Beams, slabs and columns simply 25mm to 40 100 to 120
reinforced. mm mm

3 Thin R.C.C. section or section with 75 mm to 125 125mm to

congested steel mm 150mm

25. Works strength tests shall be made in accordance with IS : 516. Each
test shall be conducted on ten specimens, five of which shall be tested at seven
days and the remaining five at 28 days The samples of concrete snail be taken
on each day of concreting and cubes shall be made at the rate of one for every
5 cubic meter of concrete or a part thereof. However, if concreting done in a
day is less than 15 cubic meter, the minimum number of cubes can be reduced
to 6 with the specific permission of the Engineer-in-charge. Similar works tests
shall be carried out whenever the quality and grading of materials is charged
16
irrespective of the quantity of concrete proud. The number of specimens may
be suitably increased as deemed necessary by the Engineer-in-charge when
procedure of tests given above reveal a poor quality of concrete and in other
special cases.

26. The average strength of the group of cubes cast for each day shall not
be less than the specified works cube-strength.

27 R.C.C. work shall have exposed concrete surface. Centering design and
its erection shall be approved by the Engineer-in-charge. One carpenter with
helper will invariably be kept present throughout the period of concreting.
Movement of labour and other persons shall be totally prohibited over
reinforcement laid in position. For access to different parts, suitable mobile
platforms shall be provided so that steel reinforcement in position is not
disturbed. For ensuring proper cover, mortar blocks of suitable size shall be
cast and tied to the reinforcement. Timber, kapchi or metal pieces shall not be
used for this purpose. Concreting of important structural members shall always
be done in the presence and under the supervision of departmental person not
below the rank of Asstt. Engineer/ Addi. Asstt. Engineer, Overseer or as
instructed by the Engineer-in-charge. After removal of form work checks that
concrete produced is of good quality plastering shall not be allowed to the
expressed faces of concrete.

28. In reinforced concrete the volume occupied by reinforcement shall not

be deducted. The slab shall be measured as running continuously through and
the beam as the portion below the slab.

29. All necessary labour, materials, equipment, etc., for sampling, preparing
test cubes, curing etc., shall be provided by the Contractor. Testing of the
materials and concrete may be arranged by the Engineer-in-charge in an
approved laboratory at the cost of the contractor.

30. The payment will be made on cubic meter basis of the finished work.
31. The unit rate for concrete shall include the cost of all materials, labour,
tools and plan required for mixing, placing in position, vibrating and compacting
finishing as-per directions of the Engineer-in-charge, curing and all other
incidental expenses for producing concrete of specified strength to complete
the structure or its components as show on the drawings and according to
these specifications. The rate shall also include the cost of making/fixing and
removing of all centers and forms required for the work.

Item No.4: - Providing & filling in foundation as base course with

ordinary cement concrete of M 15 mix and providing necessary
vertical pin headers including formwork vibrating ramming & curing
complete.
This work shall consist of Providing & filling in foundation as base course with
ordinary cement concrete of M 15 for Canal lining as per drawing including
17
formwork vibrating ramming & curing complete. It shall be carried out as per
relevant detailed specification of Item No. 3 of this contract.

The item shall be measured & paid as finished work in cubic meter.

Item No.5: - Providing and casting in situ controlled cement concrete

M-30 for R.C.C. box, Approach slab as per drawings including
centering huttering, scaffolding where necessary, laying vibrating,
curing and finishing complete.

1701. DESCRIPTION

The work shall consist of furnishing and placing structural concrete and
incidental construction in accordance with these specifications and in
conformity with the lines, grades, and dimensions, as shown -on the drawings
or as directed by the Engineer. The relevant clause No. 1100 of MORTH 5th
revision on shall be followed for pile work.

1702. MATERIALS

All materials shall conform to Section 1000 of MORT&H Specifications.

1703 GRADES OF CONCRETE

1703.1 The grades of concrete shall be designated by the characteristic

strength as given in Table 1700-1, where the characteristic strength is defined
as the strength of concrete below which not more than 5 per cent of the test
results are expected to fall.

Table 1700-1 : Grades of Concrete

Type of Concrete/Grade Designation Characteristic

Nominal Mix Standard High Strength in MPa
Concrete Concrete Performance
Concrete
M15 M15 15
M20 M20 20
M25 25
M30 M30 30
M40 M35 35
M45 M40 40
M50 M45 45
M50 50
M55 55
M60 60
M65 65
M70 70
18
 M75 75
M80 80
M85 85
M90 90

1. Nominal Mix Concrete is made on the basis of nominal mix proportioned

by weight of its main ingredients – cement, course and fine aggregates
and water.
2. Standard concrete is made on the basis of design mix proportioned by
weight of its ingredients, which in addition to cement, aggregates and
water, may contain chemical admixtures to achieve certain target values
of various properties in fresh condition, achievement of which is
monitored and controlled during production by suitable tests. Generally,
concrete of of grades up to M50 are included in this type.
3. High Performance Concrete is similar to standard concrete but contains
additional one or more mineral admixtures providing binding
characteristics and partly acting as inert filler material which increases its
strength, reduces its porosity and modifies its other properties in fresh
as well as hardened condition. Concrete of grades up to M90 are included
in this type.
4. For concrete of grades higher than M90, the design parameters may be
obtained from specialized literature and experimental results.

1703.2 The minimum grades of concrete and corresponding minimum

cement content and maximum water/cement ratios for different exposure
conditions shall be as indicated in Table 1700-2.

1703.3 For concrete subjected to sulphate attack the minimum grades of

concrete, minimum cement content and maximum eater/cement ratios and
types of cement for different concentration of sulphate content shall be as
indicated in Table 1700-3.

Table 1700-2: Requirement of Concrete for Different Exposure

Condition
Using 20mm Aggregate

Exposure Maximum Minimum Minimum Grade

Condition Water Cement of Concrete
Cement Ratio Content, kg/m3
Moderate 0.45 340 M25
Server 0.45 360 M30
Very Server 0.40 380 M40

Note:

19
 (i) All three provisions given in the above table for a particular exposure
condition, shall be satisfied.
(ii) The term cement for maximum w/c ratio and minimum cement content
shown in Table includes all cementitious materials mentioned in Clause
1715.2. The maximum limit of flyash and ground granulated blast furnace
slag in the blended cement shall be as specified in IS:1489(Part 1) and
IS:455 respectively.
(iii) For plain cement concrete, with or without surface reinforcement, the
Minimum grade of concrete can be lowered by 5MPa and maximum
water/cement ratio exceeded by 0.05.

Cement content shown in the above table shall be increased by 40 kg/m 3 for
use of 12.50 mm nominal size aggregates and decreased by 30 kg/m 3 for use
of 40mm nominal size aggregates.
Table 1700-3: Requirement of Concrete Exposed to Sulphate Attack

Class Concentration of Sulphates Type of Minimu Maximu Minimu

as SO3 Cement m m m
In Soils In (Note Cement Water / Grade of
Total SO3, in Ground ii) Content Cement Concret
SO3, 2:1 Water, kg/m3 Ratio e
% Water: g/l
Soil
Extract,
g/l
1) Traces < 1.0 < 0.3 -OPC, 280 0.5 M25
PPC or
PSC
2) 2.0 to 1.0 to 1.9 0.3 to -OPC 330 0.5 M25
0.5 1.2 PPC or
PSC
-SRPC
3) 0.5 TO 1.9 TO 1.2 TO -SRPC 330 0.5 M25
1.0 3.1 2.5 -PPC or
PSC 350 0.45 M30
4) 1.0 to 3.1 to 5.0 2.5 to -SRPC 370 0.45 M35
2.0 5.0
5) >2.0 >5.0 >5.0 -SRPC 400 0.4 M40
With
Protectiv
e
Coatings

Notes: If the requirements of maximum water/cement ratio, minimum

grade of concrete and minimum cement content from other
20
 durability considerations as given in Table 1700-2 are more
stringent than those given in this table, then the former will
govern.
OPC: Ordinary Portland Cement, PPC: Portland Pozzolona Cement.
PSC:Portland Slag Cement, SRPC: Sulphate Resisting Portland Cement.

The minimum cement content shall be as low as possible but not less than the
quantities specified in Table 1700-2 and 1700-3.

The maximum cement content excluding any mineral admixtures (Portland

cement component alone) shall not exceed 450 kg/cu.m.

1703.4 Concrete used in any component or structure shall be

specified by designation along with prescribed method of design of mix
i.e. ̒Design Mi ̓ or ̒Nominal Mix ̓. For all items of concrete, only design mix shall
be used, except where nominal mix concrete is permitted as per drawing or by
the Engineer. Nominal mix may be permitted only for minor bridges and culverts
or other incidental construction, where strength requirements are upto M 20
only. Nominal mix may also be permitted for non-structural concrete or for
screed below open foundations.

1703.5 If the contractor so proposes, the Engineer may permit the

use of concrete of higher grade than that specified on the drawing, provided
the higher grade concrete meets the specifications applicable. The additional
cost of such higher grade concrete shall be borne by the Contractor.

1704 PROPORTIONING OF CONCRETE

Prior to the start of construction, the contractor shall design the mix in case of
design mix concrete or propose nominal mix in case of nominal mix concrete,
and submit to the Engineer for approval, the proportions of materials, including
admixtures to be used at the Contractor’s option, subject to the approval of the
Engineer.

1704.1 Requirements of Consistency

The mix shall have the consistency which will allow proper placement and
compaction in the required position. Every attempt shall be made to obtain
uniform consistency. Slump test shall be used to measure consistency of the
concrete.

The optimum consistency for various types of structures shall be as indicated

in Table 1700-4, or as directed by the Engineer. The slump of concrete shall be
checked as per IS:516.
21
 Table 1700-4 : Requirements of Consistency

Type Slump (mm) (at the

Time of Placing of
Concrete)
1) a) Structure with exposed inclined surface required 25
low slump concrete to allow proper compaction
b) Plain cement concrete 25
2) RCC structure with widely spaced reinforcement, 40 - 50
e.g.
Solid columns, piers, abutments, footings, well
staining
3) RCC structure with fair degree of congestion of 50 - 75
reinforcement, e.g. pier and abutment caps, box
culverts, Well curb, well cap, walls with thickness
greater than
300 mm
4) RCC and PSC structure with highly 75 - 125
congested reinforcements e.g. deck slab girders,
box girders, walls with thickness less than 300 mm
5) Underwater concreting through tremie e.g. bottom 150 - 200
plug, Cast in-situ pilling

Notwithstanding the optimum consistency indicated against SI. No. 1 to 3, the

situation should be property assessed to arrive at the desired workability with
the adjustment of admixture in each case, where the concrete is to be
transported through transit mixer and placed using concrete pump. Under these
circumstances, the optimum consistency during placement for the items of work
of SI. No. 1 to 3, can be considered ranging from 75 mm to 150 mm. This is,
however, subject to satisfying the other essential criteria of strength, durability
etc. and approval of the Engineer.

1704.2 Requirements for Design Mixes

1704.2.1 Target Mean Strength

The target mean strength of specimen shall exceed the specified characteristic
compressive strength by at least the current margin.
i) The current margin for a concrete mix shall be
determined by the Contractor and shall be taken as 1.64
times the standard deviation of sample test results taken
from at least 40 separate batches of concrete of nominally
similar proportions produced at site by the same plant
under similar supervision, over a period exceeding 5 days,
but not exceeding 6 months.

22
 ii) Where there is insufficient data to satisfy the above, the
current margin for the initial design mix shall be taken
as given in Table 1700-5:
Table 1700-5 : Current Margin for Initial Design Mix

Concrete Current Margin Target Mean Strength

(MPa) (MPa)
M 15 10 25
M 20 10 30
M 25 11 36
M 30 12 42
M 35 12 47
M 40 12 52
M 45 13 58
M 50 13 63
M 55 14 69
M 60 14 74
M 65 15 80
M 70 15 85
M 75 15 90
M 80 15 95
M85 16 101
M90 16 106

The initial current margin given in Table 1700-5 shall be used till sufficient
data is available to determine the current margin as per Sub-Clause
1704.2.1(i).

1704.2.2 Trial mixes

The Contractor shall give notice to the Engineer to enable him to be present at
the time of carrying out trial mixes and preliminary testing of the cubes. Prior
to commencement of trial mix design, all materials forming constituents of
proposed design mix should have been tested and approval obtained in writing
from the Engineer. Based on that results of material, draft mix design
calculation for all grades of concrete to be used in the works, shall be prepared
after taking into account the provisions in the contract Technical Specifications,
Guidelines of IS:10262, IS:SP:23 and IRC:112 and submitted to the Engineer
for approval. Prior to commencement of concreting, trial mix design shall be
performed for all grades of concrete and trial mix which has been found
successful, shall be submitted by the Contractor and approval obtained. During
concreting with the approved trial mix design, if source of any constituents is
changed, the mix design shall be revised and tested for satisfying the strength
requirements.

23
The initial trial mixes shall be carried out in a laboratory approved by the
Engineer. However, Engineer may permit the initial trial mixes to be prepared
at the site laboratory of the Contractor, if a full-fledged concrete laboratory has
been established well before the start of construction, to his entire satisfaction.
Sampling and testing procedures shall be in accordance with these
specifications.

When the site laboratory is utilized for preparing initial mix design, the
concreting plant and means of transport employed to make the trial mixes shall
be similar to that proposed to be used in the works.
For each trial mix, a set of six cubes shall be made from each of three
consecutive batches for purposes of testing. Three cubes from each set of six
shall be tested at an age of 28 days and three at an earlier age approved by
the Engineer. The cubes shall be made, cured, stored, transported and tested
in accordance with these Specifications. The mean strength of the nine cubes
at 28 days shall exceed the specified characteristic strength by the current
margin minus 3.5 MPa.

1704.2.3 Control of strength of design mixes

(a) Adjustment to Mix Proportions
Adjustments to mix proportions arrived at in the trial mixes shall be
made subject to the Engineer’s approval, in order to minimize the
variability of strength and to maintain the target mean strength.
Such adjustments shall not be taken to imply any change in the
current margin.

(b) Change of Current Margin

When required by the Engineer, the Contractor shall recalculate the
current margin in accordance with Clause 1704.2.1. The
recalculated value shall be adopted as directed by the Engineer, and
it shall become the current margin for concrete produced thereafter.

(c) Additional Trial Mixes

In case any changes are observed in the properties of fresh
concrete and/or strength of hardened concrete on the basis of
early age tests, additional mixes and tests shall be carried out
during production, so as to control and bring the quality of
concrete within acceptable limits. In case of any change in the
source or properties of materials, the design of mix shall be
established afresh.
1704.3 Requirements of Nominal Mix Concrete

Requirements for nominal mix concrete unless otherwise specified shall be as

given in Table 1700-6.

24
 Table 1700-6 : Requirements for Nominal Mix Concrete

Concrete Total Quantity of Dry Proportion of Fine Maximum

Grade Aggregate by Mass per 50 to Coarse Quantity
kg of Cement to be taken Aggregate (by of Water for 50
as the Sum of Individual Mass) kg
Masses of Fine and Coarse of cement (Liters)
Aggregates (kg) PCC RCC

M 15 350 Generally 1:2, 25

subject to upper
M 20 250 limit 1:1.5 and 25 22
lower limit of
1:2.5
1704.4 Additional Requirements

Concrete shall meet with any other requirements as specified on the drawing
or as directed by the Engineer. Additional requirements shall also consist of the
following Overall limits of deleterious substances in concrete:

(a) Total acid soluble chloride contemt in the concrete mix

expressed as chloride ions shall not exceed the following
values by mass of cement.

• Prestressed Concrete : 0.10

percent
• Reinforced concrete (in sever, very sever
or extreme exposure condition) : 0.20
percent
• Reinforced concrete in moderate exposure
Condition : 0.30
percent

(b) The total water soluble sulphate content of the concrete mix
expressed as S03, shall not exceed 4 percent by mass of
cement in the mix.

For concrete made with Portland pozzolona cement, Portland blast furnace slag
cement or mineral admixtures. the setting time and rate of gain of strength are
different form those for concrete made with OPC alone. Such modified
properties shall be taken into account while deciding the de-shuttering time,
curing period, early age loading and time of prestressing. Additional cube
samples may be required to be taken for verifying the concrete properties.

25
1704.5 Suitability of Proposed Mix Proportions

The Contractor shall submit the following information for the Engineer’s
approval:
a) Nature and source of each material
b) Quantities of each material per cubic meter of fully
compacted concrete
c) Either of the following :

(i) appropriate existing data as evidence of satisfactory

previous performance for the target mean strength,
current margin, consistency and water/cement ratio and
any other additional requirements) as specified
(ii) Full details of tests on trial mixes.

d) Statement giving the proposed mix proportions for

nominal mix concrete

Any change in the source of material or in the mix proportions shall be subject
to the Engineer’s prior approval.

1704.6 Checking of Mix Proportions and Water/Cement Ratio

In proportioning concrete, the quantity of both cement and aggregate shall be

determined by weight. Where the weight of cement per bag as given by the
manufacturer is accepted, a reasonable number of bags shall be weighed
separately to check the net weight. Where cement is weighed from bulk stock
at site and not by bag, it shall be weighed separately from the aggregates.
Water shall either be measured by volume in calibrated tanks or weighed. All
measuring equipment shall be maintained by in a clean and serviceable
condition. Their accuracy shall be periodically checked.

The specified water/cement ratio shall always be kept constant and at its
correct value. To this end, moisture content in both fine and coarse aggregates
shall be determined as frequently as possible, the frequency for a given job
being determined by the Engineer according to the weather conditions. The
amount of water to be added shall then be adjusted to compensate for
variations in moisture content. For the determination of moisture content in the
aggregates IS:2386 (Part lll) shall be referred. Suitable adjustments shall also
be made in the weight of aggregates to allow for their variation in their moisture
content.

1704.7 Grading of aggregates for Pumped Concrete

Materials for pumped concrete shall be batched consistently and uniformly.

26
Maximum size of aggregate shall not exceed one-third of the internal diameter
of the pipe.

The grading of aggregates shall be continuous and shall have sufficient ultra-
fine materials (material finer than 0.25 mm). Proportion of fine aggregates
passing through 0.25 mm shall be between 15 and 30 percent and that passing
through 0.125 mm sieve shall not be less 5 percent of the total volume of
aggregate. Admixtures to increase workability can be added. When pumping
long distance and in hot weather, set-retarding admixtures can be used. Fluid
mixes can be pumped satisfactory after adding plasticisers. Suitability of
concrete shall be verified by trial mixes and by performing pumping test.

1705 ADMIXTURES

1705.1 Chemical Admixtures

Chemical admixtures such as super plasticisers, or air entraining, water

reducing, accelerating and retarding agents for concrete, may be used with the
approval of the Engineer.

As the selection of an appropriate concrete admixture is an integral part of the

mix design, the manufacturers shall recommend the use of any one of their
products only after obtaining complete information of all the actual constituents
of concrete as well as methodologies of manufacture, transportation and
compaction of concrete proposed to be used in the work. Admixtures/additives
conforming to IS:9103 may be used subject to approval of the Engineer.
However, admixtures/additives generating hydrogen or nitrogen and containing
chlorides, nitrates, sulphides, sulphates or any other material likely to
adversely affect the steel or concrete, shall not be permitted.

The general requirements for admixtures are given in Clause 1007 of these
Specifications.

Compatibility of the admixtures with the cement and any other pozzolona or
hydraulic addition shall be ensured by for avoiding the following problems

i) Requirement of large dosage of

superplasticiser for achieving desired workability.
ii) Excessive retardation of setting.
iii) Excessive entrainment of large air bubbles.
iv) Unusually rapid stiffening of concrete.
v) Rapid loss of slump
vi) Excessive segregation and bleeding.

27
 1705.2 Mineral Admixtures

For use of mineral admixtures, refer Clauses 1714.1 and 1715.2.

1706 SIZE OF COARSE AGGREGATE

The size (maximum nominal) of coarse aggregates for concrete to used in

various components shall be given as Table 1700-7.
TABLE 1700-7 : Maximum Nominal Size of Coarse Aggregates
Maximum Nominal Size
Components of Coarse Aggregate
(mm)
i) RCC well curb 20
ii) RCC/PCC well staining 40
iii) Well cap or Pile Cap Solid type piers and 40
abutments
iv) RCC work in girders, slabs, wearing coat, 20
kerb, approach slab, hollow piers and
abutments, pier/abutment caps, piles
v) PSC work 20
vi) Any other item As specified by the Engineer

Maximum nominal size of aggregates shall also be restricted to the smaller of

the following values :

a) 10 mm less than the minimum lateral clear distance between

main reinforcements

b) 10 mm less than the minimum clear cover to the reinforcements

c) One quarter of minimum thickness of member

The proportions of the various individual size of aggregates shall be so adjusted

that the grading produces densest mix and the grading curve corresponds to
the maximum nominal size adopted for the concrete mix.

28
1707. EQUIPMENT

Unless specified otherwise, equipment for production, transportation and

compaction of concrete shall be as under:

a) Production of Concrete:

i) For overall bridge length of less than 200 m – batch type

concrete mixer, diesel or electric operated, with a minimum size
of 200 liters automatic water measuring system and integral
weighed (hydraulic/pneumatic type)

ii) For overall bridge length of 200 m or more – concrete batching

and mixing plant fully automatic, with minimum capacity of 15
cum per hour.

All measuring devices of the equipment shall be maintained in a clean and

serviceable condition. Its accuracy shall be checked over the range in use, when
set up at each site and thereafter periodically as directed by the Engineer.

The accuracy of the measuring devices shall fall within the following limits:
Measurement of Cement :± 3 percent of the quantity of
cement in each batch

Measurement of Water : ± 3 percent of the quantity of

water in each batch

Measurement of Aggregate : ± 3 percent of the quantity of

aggregate in each batch

Measurement of Admixture : ± 3 percent of the quantity of

admixture in each batch

b) Transportation of Concrete :
i) Concrete dumpers minimum 2 tonnes capacity
ii) Powered hoists minimum 0.5 tonnes capacity Chutes
iii) Buckets handled by cranes
iv) Transit truck mixer
v) Concrete pump
vi) Concrete distributor booms
vii) Belt conveyor

29
 viii) Cranes with skips
ix) Tremies
c) For Compaction of Concrete :
i) Internal vibrators size 25mm to 70mm
ii) Form vibrators minimum 500 watts
iii) Screed vibrators full width of carriageway (upto two lanes)

1708 BATCHING, MIXING, TRANSPORTING, PLACING AND

COMPACTION

1708.1 General

Prior to start of concreting, the Contractor shall submit for approval of the
Engineer, his programme along with list of equipment proposed to be used by
him for batching, mixing, transporting and placing concrete.

1708.2 Batching of Concrete

In batching concrete:

• The quantity of cement, aggregate and mineral admixtures,

if used,
shall be determined by mass.
• Chemical admixtures, if solid, shall be determined by mass.
• Liquid admixtures may be measured in volume or mass, and
• Water shall be weighed or measured by volume in a
calibrated tank.
The concrete shall be sourced from on-site or off-site batching and mixing
plants, or from approved Ready Mixed Concrete plants, preferably having
quality certification.

Except where supply of properly graded aggregate of uniform quality can be

maintained over a period of work, the grading of aggregate should be controlled
by obtaining the coarse aggregate in different sizes and blending them in the
right proportions when required, the different sizes being stocked in separate
stock piles. The materials should be stock piled several hours, preferably a day
before use. The grading of coarse and fine aggregate should be checked as
frequently as possible to ensure that the specified grading is maintained.

30
The water/cement ratio shall always be maintained constant at its correct value.
To this end, determination of moisture content in both fine and coarse
aggregates shall be made as frequently as possible, depending on weather
conditions. The amount of added water shall be adjusted to compensate for any
observed variations in the moisture content. To allow for the variation in mass
of aggregate due to variation in moisture content, suitable adjustment in the
mass of aggregate, shall also be made. Accurate control shall be kept on the
quantity of mixing water, which when specified, shall not be changed without
approval.

1708.3 Mixing Concrete

1708.3.1 Mixing at Site

All concrete shall be machine mixed. In order to ensure uniformity and good
quality of concrete the ingredients shall be mixed in a power driven batch mixer
with hopper and suitable weigh batching arrangement or in a central mix plant.
Hand mixing shall not be permitted. The mixer pr the plant shall be at an
approved location considering the properties of the mixes and the transportation
arrangements available with the contractor. The mixer or the plant shall be
approved by the Engineer.

Mixing shall be continued till materials are uniformly distributed and a uniform
colour of the entire mass is obtained, and each individual particle of the coarse
aggregate shows complete coating of mortar containing its proportionate
amount of cement. In no case shall mixing be done for less than 2 minutes. It
shall be ensured that the mixers are not loaded above their rated capacities and
are operated at a speed recommended by the manufacturer. When mineral
admixtures are added at the mixing stage, their thorough and uniform blending
with cement shall be ensured, if necessary by longer mixing time. The addition
of water after the completion of the initial mixing operation, shall not be
permitted.

Mixers which have been out of use for more than 30 minutes shall be thoroughly
cleaned before putting in a new batch and also before changing from one type
of cement to another.

1708.3.2 Ready Mix Concrete

Use of ready mix concrete proportioned and mixed off the project site and
delivered to site in a freshly mixed and unhardened state conforming to IS:4926,
shall be allowed with the approval of the Engineer.

31
1708.4 Transporting Concrete

Mixed concrete shall be transported from the place of mixing to the place of final
deposit as rapidly as possible by methods which will prevent the segregation or
loss of the ingredients. The method of transporting or placing of concrete shall
be approved by the Engineer. Concrete shall be transported and placed as near
as practicable to its final position so that no contamination, segregation or loss
of its constituents materials take place.

Concrete may be transported by transit mixers or properly designed buckets or

by pumping. Transit mixers or other hauling equipment when used should be
equipped with the means of discharge of concrete without segregation. During
hot or cold weather, concrete shall be transported in deep containers. Other
suitable methods to be reduce the loss of water by evaporation in hot weather
and heat loss in cold weather may also be adopted.

When concrete is conveyed by chute, the plant shall be of such size and design
as to ensure practically continuous flow. Slope of the chute be so adjusted that
the concrete flows without excessive quantity of water and without any
segregation of its ingredients. The delivery end of the chute shall be as close as
possible to the point of deposit. The chute shall be thoroughly flushed with water
before and after each working period and the water used for this purpose shall
be discharged outside the formwork.

In case concrete is to be transported by pumping, the fresh concrete should

have adequate fluidity and cohesiveness to be pumpable. Proper concrete mix
proportioning and initial trials should ensure this. The conduit shall be primed by
pumping a batch of mortar through the line to lubricate it. Once the pumping is
started, it shall not be interrupted, as concrete standing idle in the line is liable
to cause plug. The operator shall ensure that some concrete is always there in
the pump’s receiving hopper during operation. The lines shall always be
maintained clean and free of dents.

Pipelines from the pump to the placing area shall be laid with minimum bends.
For large quantity placements, standby pumps shall be available. Suitable air
release valves, shutoff valves etc. shall be provided as per site requirements.
The pumping of priming mix i.e. rich mix of creamy consistency, to lubricate the
concrete pump and pipelines, shall precede the pumping of concrete. Continuous
pumping shall be done to the extent possible. After concreting, the pipelines and
accessories shall be cleaned immediately. The pipes for pumping shall not be
made of material which has adverse effect on concrete. Aluminum alloy pipelines
shall not be used.

32
1708.5 Placing of Concrete

All formwork and reinforcement contained in it shall be cleaned and made free
from standing water, dust, snow or ice immediately before placing of concrete.

No concrete shall be placed in any part of the structure until the approval of the
Engineer has been obtained. if concreting is not started within 24 hours of the
approval being given, it shall have to be obtained again from the Engineer.
Concreting then shall proceed continuously over the area between the
construction joints. Fresh concrete shall not be placed against concrete which
has been in position for more than 30 minutes unless a proper construction joint
is formed.

The concrete shall be deposited as nearly as practicable in its original position to

avoid re-handling. Methods of placing should be such as to preclude segregation.
Care should be take to avoid displacement of reinforcement or movement of
formwork. To achieve this, concrete should be lowered vertically in the form and
horizontal movement of concrete inside the forms should, as far as practicable,
be minimized.

The concrete shall be placed and compacted before its initial setting so that it is
amenable to compaction by vibration. The workability of concrete at the time of
placement shall be adequate for the compaction equipment to be used. If there
is considerable time gap between mixing and placing of concrete, as in the case
of ready mixed concrete plants or off-site batching and mixing plants, concrete
mix shall be designed to have appropriately higher workability at the time of
discharge from the mixer, in order to compensate the loss of workability during
transit. This is generally achieved by suitable chemical admixtures. Keeping
these considerations in view, the general requirement for ready mixed concrete
plants or off-site batching and mixing plants, is that concrete shall be discharged
from the truck mixer within two hours of the time of loading. A longer period
may be permitted if suitable retarding admixtures are used.

In the wall forms, drop chutes attached to hoppers at the top should preferably
be used to lower concrete to the bottom of the form. As a general guidance, the
permissible free fall of concrete may not exceed 1.5 meters and under no
circumstances shall it be more than 2 meters. When free fall of larger height is
involved, self compacting concrete having adequate fluidity, cohesiveness and
viscosity and which uniformly and completely fills every corner of the formwork
by its own weight without segregation, shall be used.

Except where otherwise agreed to by the Engineer, concrete shall be deposited

in horizontal layers to a compacted depth of not more than 450 mm when
internal vibrators are used and not exceeding 300 mm in all other cases.

33
Concrete when deposited shall have a temperature of not less than 5 o C and
preferably not more than 30o C and in no case more than 40oC. It shall be
compacted in its final position within 30 minutes of its discharge from the mixer,
unless carried in properly designed agitators, operating continuously, when this
time shall be within 1 hour of the addition of cement to the mix and within 30
minutes of its discharge from the agitator. It may be necessary to add retarding
admixtures to concrete if trials show that the periods indicated above are
unacceptable. In all such matters, the Engineer’s decision shall be final.

1708.6 Compaction of Concrete

Concrete shall be thoroughly compacted by vibration or other means during

placing and worked around the reinforcement, tendons or duct formers,
embedded fixtures and into corners of the formwork to produce a dense
homogeneous void-free mass having the required surface finish. When vibrators
are used, vibration shall be done continuously during the placing of each batch
of concrete until the expulsion of air has practically ceased and in a manner that
does not promote segregation. Over vibration shall be avoided to minimize the
risk of forming a weak surface layer. When external vibrators are used, the
design of formwork and disposition of vibrator shall be such as to ensure efficient
compaction and to avoid surface blemishes. Vibrations shall not be applied
through reinforcement and where vibrators of immersion type are used, contact
with reinforcement and all inserts like ducts etc. shall be avoided.

When internal vibrators are used, they shall be inserted vertically to the depth
of the layer being placed and ordinarily shall penetrate the layer below for a few
centimeters. The vibrator should be kept in place until air bubbles cease escaping
from the surface and then withdrawn slowly to ensure that no hole is left in the
concrete, care being taken to see that it remains in continued operation while
being withdrawn. The internal vibrators shall be inserted in an orderly manner
and the distance between insertions should be about one and a half times the
radius of the area visibly affected by vibration. Additional vibrators in serviceable
condition shall be kept at site so that they can be used in the event of
breakdowns.

Mechanical vibrators used shall comply with IS:2502, IS:2506, 1S:2514 and
IS:4656.

1709. CONSTRUCTION JOINTS

Construction joints shall be avoided as far as possible. In no case shall the

locations of such joints shall be changed or increased from those shown on the
drawings except with express approval of the Engineer.

Joints should be positioned where they are readily accessible for preparation and
concreting. Construction joints should be positioned to minimize the effects of
34
the discontinuity of the durability, structural integrity and appearance of the
structure. As far as possible, joints should be provided in non-aggressive zones,
but if joints in aggressive zones cannot be avoided, they should be sealed. Joints
should be located away from the regions of maximum stress caused by loading;
particularly where shear and bond stresses are high.

In beams and slabs joints should not be near the supports. Construction joints
between slabs and ribs in composite beams, shall be avoided. For box girders,
there shall be no construction joint between the soffit and webs.

Joints should be either vertical or horizontal. For a vertical construction joint, the
lifts of concrete shall finish level or at right angles to the axis of the member.
Concreting shall be continued right up to the joint.

Before resuming work at a construction joint when concrete has not yet fully
hardened, All laitance shall be removed thoroughly. The surface shall be
roughened, taking care to avoid dislodgement of coarse aggregates. Concrete
shall be brushed with a stiff brush soon after casting, while the concrete has only
slightly stiffened. If the concrete has partially hardened, it may be treated by
wire brushing or with a high pressure water jet, followed by drying with an air
jet, immediately before the new concrete is placed. Fully hardened concrete shall
be treated with mechanical hand tools or grit blasting, taking care not to split or
crack aggregate particles. The Practice of first placing a layer of mortar or grout
when concreting joints, shall be avoided. The old surface shall be soaked with
water, without leaving puddles, immediately before starting concreting. The new
concrete shall be thoroughly compacted against it.

Where there is likely to be a delay before placing the next concrete lift,
protruding reinforcement shall be protected. In all cases, where construction
joints are made, the joint surface shall not be contaminated with release agents,
dust, or sprayed curing membrane and reinforcement shall be firmly fixed in
position at the correct cover.

The sequence of concreting, striking of forms and positioning of construction

joints for every individual structure, shall be decided well in advance of the
commencement of work.

1710 CONCRETING UNDER WATER

When it is necessary to deposit concrete under water, the methods, equipment,

materials and proportions of mix to be used, shall be got approved from the
Engineer before any work
is started.
Concrete shall not be placed in water having a temperature below 5°C. The
temperature of the concrete, when deposited, shall not be less than 16°C, nor
more than 30°C.

35
Coffer dams or forms shall be sufficiently tight to ensure still water conditions, if
practicable, and in any case to reduce the flow of water to less than 3 m per
minute through the space into which concrete is to be deposited. Coffer dams
or forms in still water shall be sufficiently tight to prevent loss of mortar through
the joints in the walls. Pumping shall not be done while concrete is being placed,
or until 24 hours thereafter. To minimise the formation of laitance, care shall be
exercised not to disturb the concrete as far as possible while it is being deposited.

All under water concreting shall be carried out by tremie method only. The
number and spacing of the tremies should be worked out to ensure proper
concreting. However, it is necessary to have a minimum number of 2 tremies for
any concreting operation, so that even if one of the tremies goes out of
commission during concreting, the other one can be used to complete the work.
The tremie concreting when started, should continue without interruption for the
full height of the member being concreted. The capacity of the concrete
production and placement equipment should be sufficient to enable the
underwater concreting to be completed uninterrupted within the stipulated time.

The top section of the tremie shall have a hopper large enough to hold one full
batch of the mix or the entire contents of the transporting bucket, as the case
may be. The tremie pipe shall not be less than 200 mm in diameter and shall be
large enough to allow a free flow of concrete and strong enough to withstand
the external pressure of the water in which it is suspended, even if a partial
vacuum develops inside the pipe. Preferably, flanged steel pipe of adequate
strength shall be used. A separate lifting device shall be provided for each tremie
pipe with its hopper at the upper end. Unless the lower end of the pipe is
equipped with an approved automatic check valve, the upper end of the pipe
shall be plugged with a wadding of gunny sacking or other approved material
before delivering the concrete to the tremie pipe through the hopper, so that
when the concrete is forced down from the hopper to the pipe, it will force the
plug (and along with it any water in the pipe) down the pipe and out of the
bottom end, thus establishing a continuous stream of concrete. It will be
necessary to raise the tremie slowly in order to allow a uniform flow of concrete.
At all times after placing of concrete is started and until all the required quantity
has been placed, the lower end of the tremie pipe shall be kept below the surface
of the plastic concrete and shall not be taken out of concrete. This will cause the
concrete to build up from below instead of flowing out over the surface and thus
avoid formation of layers of laitance. It is advisable to use retarders or suitable
superplasticizers to retard the setting time of concrete, which shall be established
before the commencement of work.

36
1711 CONCRETING IN EXTREME WEATHER

1711.1 Concreting in Cold Weather

Where concrete is to be deposited at or near freezing temperature, precautions

shall Be taken to ensure that at the time of placing, it has a temperature of not
less than 5°C and that the temperature shall be maintained above 4°C until the
concrete has hardened. When necessary, concrete ingredients shall be heated
before mixing but cement shall not be heated artificially other than by the heat
transmitted to it from other ingredients of the concrete. Stock piled aggregate
may be heated by the use of dry heat or steam. Aggregates shall not be heated
directly by gas or on sheet metal over fire. In general, the temperature of
aggregates or water shall not exceed 65°C. Salt or other chemicals shall not be
used for the prevention of freezing. No frozen material or materials containing
ice shall be used. All concrete damaged by frost shall be removed. Concrete
exposed to freezing weather shall have entrained air and the water content of
the mix shall not exceed 30 liters per 50 kg of cement. To counter slower setting
of concrete, accelerators can be used with the approval of the Engineer.
However, accelerators containing chloride shall not be used.

1711.2 Concreting in hot Weather

When depositing concrete in hot weather, precautions shall be taken sa that the
temperature of wet concrete does not exceed 30°C while placing. This shall be
achieved by using chilled mixing water, using crushed ice as a part of mixing
water, shading stock piles of aggregates from direct rays of the sun, sprinkling
the stock piles of coarse aggregate with water to keep them moist, limiting
temperature of cement below 30°C at the time of use, starting curing before
concrete dries out and restricting time of concreting as far as possible to early
mornings and late evenings. When ice is used to cool mixing water, it will be
considered as part of the water in design mix. Under no circumstances shall the
mixing operation be considered complete until all ice in the mixing drum has
melted. The Contractor will be required to state his methodology for the
Engineer’s approval when temperatures of concrete are likely to exceed 30 oC
during the work.
1712 PROTECTION AND CURING

1712.1 General

Concreting operations shall not commence until adequate arrangements for

concrete curing have been made by the Contractor. Curing and protection of
concrete shall start immediately after compaction of the concrete.

The concrete shall be protected from:

37
 a) Premature drying out particularly by solar radiation and
wind
b) High internal thermal gradients
c) Leaching out by rain and flowing water
d) Rapid cooling during the first few days after placing
e) Low temperature or frost
f) Vibration and impact which may disrupt the concrete and
interfere with its bond to the reinforcement.
g) Vibration caused by traffic including construction traffic.
Concrete shall be protected, without allowing ingress of external water, by
means of wet (not dripping) gunny bags, hessian etc. Once the concrete has
attained some degree of hardening (approximate 12 his after mixing), moist
curing shall commence and be continued through the requisite period. Where
members are of considerable size and length, with high cement content,
accelerated curing methods may be applied, as approved by the Engineer.

1712.2 Water Curing

Water for curing shall be as specified in Section 1000 of these specifications.

Sea water shall not be used for curing. Sea water shall not come into contact
with concrete members before they have attained adequate strength.

The concrete should be kept constantly wet by ponding or covering or use of

sprinklers/ perforated pipes for a minimum period of 14 days after concreting,
except in the case of concrete with rapid hardening cement, where it can be
reduced to 5 days. Water should be applied on surfaces after the final set. Curing
through watering shall not be done on green concrete. On formed surfaces,
curing shall start immediately after the forms are stripped. The concrete shall be
kept constantly wet with a layer of sacking, canvas, hessian or similar absorbent
material.

1712.3 Steam Curing

Where steam curing is adopted, it shall be ensured that it is done in suitable

enclosure to contain the live steam in order to minimize moisture and heat
losses. The initial application of the steam shall be after about four hours of
placement of concrete to allow the initial set of the concrete to take place.

Where retarders are used, the waiting period before application of the steam
shall be increased to about six hours.

38
The steam shall be at 100 percent relative humidity to prevent loss of moisture
and to provide excess moisture for proper hydration of the cement. The
application of steam shall not be directly on the concrete. Steam curing is
applied in enclosures or tunnels through which concrete members are
transported on a conveying system. Alternatively, portable enclosures or plastic
covers are placed over precast members and steam is supplied to the
enclosures. The rate of increase or decrease of temperature should not be more
than 10°C to 20°C per hour and the maximum temperature shall be about 70°C.
The maximum temperature shall be maintained until the concrete has attained
the desired strength required at the end of steam curing period and shall be
decided by prior trials. When steam curing is discontinued, the air temperature
shall not drop at a rate exceeding 10°C per hour, until a temperature of about
10°C above the ambient temperature outside has been reached. Steam curing
of concrete shall be followed by water curing for at least 7 days. The concrete
shall not be exposed to temperatures below freezing for at least six days after
curing.

1712.4 Curing Compound

Membrane forming curing compounds consisting of waxes, resins, chlorinated
rubbers etc. may be permitted by the Engineer in special circumstances. Curing
compounds shall not be used on any surface which requires further finishing to
be applied. All construction joints shall be moist cured and no curing compound
shall be permitted in locations where concrete surfaces are required to be
bonded together.

Liquid membrane forming compounds shall conform to ASTMC 309 and the
curing efficiency shall be as per ASTMC 156.

Curing compounds shall be continuously agitated during use. All concrete cured
by this method shall receive two applications of the curing compound. The first
coat shall be applied immediately after acceptance of concrete finish. If the
surface is dry, the concrete shall be saturated with water and curing compound
applied as soon as the surface film of water disappears. The second application
shall be made after the first application has set. Placement in more than two
coats may be required to prevent streaking. The membrane formed shall be
stripped off after 14 days, when curing is complete. Impermeable membranes,
such as sheet materials for curing concrete conforming to ASTM C 171 or
polyethylene sheeting covering closely the concrete surface, may also be used
to provide effective barrier against evaporation.

1713 FINISHING

Immediately after the removal of forms, exposed bars or bolts, if any, shall be
cut inside the concrete member to a depth of at least 50 mm below the surface
of the concrete and the resulting holes filled with cement mortar. All fins caused
by form joints, all cavities produced by the removal of form ties and all other
39
holes and depressions, honeycomb spots, broken edges or corners, and other
defects, shall be thoroughly cleaned, saturated with water and carefully pointed
and rendered true with mortar. The mortar shall be of cement and fine
aggregate mixed in the proportions used in the grade of concrete that is being
finished and of as dry a consistency as possible. Considerable pressure shall be
applied in filling and pointing to ensure thorough filling in all voids. Surfaces
which have been pointed shall be kept moist for a period of twenty four hours.
Special pre-packaged proprietary mortars shall be used where appropriate or
where specified in the drawing.

All construction and expansion joints in the completed work shall be left
carefully tooled and free from any mortar and concrete. Expansion joint filler
shall be left exposed for its full length with clean and true edges.

Immediately on removal of forms, the concrete work shall be examined by the

Engineer before any defects are made good. The work that has sagged or
contains honeycombing to an extent detrimental to structural safety or
architectural appearance of the member, shall be rejected. Surface defects of
a minor nature may be accepted. On acceptance of such work, the same shall
be rectified as directed by the Engineer.

1714 CONCRETE WITH BLENDED CEMENTS OR MINERAL

ADMIXTURES

1714.1 Production of Concrete

In order to improve the durability of the concrete, use of blended cement or

blending of mineral admixtures, is permitted. The maximum limit of flyash and
ground granulated blast furnace slag in concrete, shall be as specified in Clause
1715.2. Blending at site shall be permitted only through a specific facility with
complete automated process control to achieve the specified design quality or
through RMC plants with similar facility.

1714.2 Modified Properties

For concrete made with Portland Pozzolona Cement, Portland Blast furnace slag
cement or mineral admixtures, the setting time and rate of gain of strength are
different from those of concrete made with OPC alone. Cognizance of such
modified properties shall be taken in deciding de-shuttering time, initial time of
prestressing, curing period and for early age loading.

40
1714.3 Compatibility of Chemical Admixtures

Compatibility of chemical admixtures and superplasticizers with Portland

Pozzolona cement, Portland blast furnace slag cement and mineral admixtures
shall be ensured by trials outlined in Clause 1705.

1714.4 Additional Tests

In addition to the strength tests prescribed in other Sections of these

Specifications, the following additional tests are required to be carried out from
considerations of durability.

i) Rapid Chloride Ion Permissibility Test

Rapid Chloride Ion permeability test on as per ASTM C 1202 at 56
days for extreme, very severe and severe conditions of exposure.
The permissible value of Chloride-Ion permeability for extreme
condition 800 Coulombs very severe condition 1200 coulombs and
severe exposure condition 1500 coulombs.

ii) Water Permeability Test

Water permeability test as per DIN: 1048 Part 5-1991 shall be
carried out as described in Clause 1717.2.5.5.

1715 HIGH PERFORMANCE CONCRETE

1715.1 General

High Performance Concrete shall be used where special performance

requirements of high strength, high early strength, high workability, low
permeability and high durability for severe service environments, are required.
Production and use of such concrete in the field shall be carried out with high
degree of uniformity between batches and very stringent quality control.

1715.2 Materials

Cement, mineral admixtures, chemical admixtures, aggregates and water shall

conform to Section 1000 of these Specifications and this Section.

Flyash when used, shall neither be less than 20 percent nor shall be greater
than 35 percent of the total by mass of ordinary Portland cement and fiyash
and shall conform to grade-1 of IS:3812.

Ground granulated blast furnace (GGBS) slag when used, shall neither be less
than 50 percent nor greater than 70 percent of the total mass of ordinary
Portland cement and GGBS and shall conform to 1S:12089, Silica fume
conforming to IS:15388 shall be used.

41
 The cement content of concrete inclusive of any mineral admixtures shall not
be less than 380 kg/m3. The cement content excluding any mineral admixtures
(Portland cement content alone) shall not exceed 450 kg/m3. The
water/cement (cement plus all cementitious materials) ratio should generally
not exceed 0.33 but in no case shall be more than 0.40.

1715.3 Compatibility of Admixtures

Compatibility of the superplasticizer and admixtures with the cement and any
other Pozzolanic or hydraulic dilutes shall be ensured by trials as outlined under
Clause 1705.

1715.4 Characteristic Strength and Target Mean Strength

Characteristic strength and the initial target mean strength of concrete, shall
be as given in Table 1700-8. The target mean strength shall be calculated as
per Clause 1704.2 after obtaining data on standard deviation from sufficient
samples.

Table 1700-8 : Characteristic Compressive Strength and Target Mean

Strength
Grade Specified Characteristic Target Mean Strength (MPa)
Designation Compressive Strength at 28 days
(MPa)
M 40 40 52
M 45 45 58
M 50 50 63
M 55 55 69
M 60 60 74
M 65 65 80
M 70 70 85
M 75 75 90
M 80 80 95
M 85 85 101
M 90 90 106

1715.5 Workability and Other Requirements

Workability, concrete mix design, field trial mixes, chloride and sulphate
contents shall be as laid down in other Sections of these Specifications.

1715.6 Mixing of Concrete

The concreting plant and means of transportation employed to make trial mixes
and to transport them to representative distances shall be similar to the
42
corresponding plant and transport to be used in the works. The optimum
sequence of mixing of ingredients shall be established by trials. Mixing time
may be longer than in normal grade concrete mixes.

The temperature of concrete at the time of placement shall not exceed 25°C.
The temperature of concrete at the mixing stage should be lower, to allow for
rise in temperature during transport. When considerable distance of transport
is involved, particular attention should be paid to ensure retention of slump as
targeted for placement.

1715.7 Prototype Testing

Mock-up trials or prototype testing may be carried out to ensure that the
concrete can be satisfactorily placed and compacted, taking into account the
location of placement and provision of reinforcement, and required adjustments
made in concrete mix design and/or detailing of reinforcement.

1715.8 Curing of Concrete

High performance concrete containing silica fume is more cohesive than normal
mixes hence, there is a little or no bleeding and no bleed water to rise to the
surface to offset water loss due to evaporation. Plastic shrinkage cracking is
possible, if curing is not proper. Initial curing should commence soon after initial
setting of concrete. Concrete should be covered with moist covers, opaque
colour plastic sheets or suitable curing compound. Final moist curing should
commence after final setting of concrete and continue for at least 14 days.

1715.9 Additional Tests for Concrete

Apart from the strength tests prescribed in other Sections of these
Specifications, the additional tests as specified under Clause 1714.3, shall also
be carried out.
1716 TOLERANCES

Tolerances for dimensions/shape of various components shall be as indicated

in these Specifications or shown on the drawings or as directed by the Engineer.

1717 TESTS AND STANDARDS OF ACCEPTANCE

1717.1 Concrete shall conform to the surface finish and tolerance as
prescribed in these Specifications for respective components.
1717.2 Random sampling and lot by lot acceptance inspection, shall be
made for the 28 days cube strength of concrete.

43
1717.3 Concrete under acceptance, shall be notionally divided into lots
for the purpose of sampling before commencement of work. The basis of
delimitation of lots shall be as follows:
i) No individual lot shall be more than 30 cu.m in volume
ii) Different grades of mixes of concrete shall be divided into
separate lots.
iii) Concrete of a lot shall be used in the same identifiable
component of the bridge.

1717.4 Sampling and Testing

Concrete for preparing 3 test cubes shall be taken from a batch of concrete at
point of delivery for construction, according to procedure laid down in IS:1199.

A random sampling procedure shall be adopted which ensures that each of the
concrete batches forming the lot under acceptance inspection has equal chance
of being chosen for taking cubes.

150 mm cubes shall be made, cured and tested at the age of 28 days for
compressive strength in accordance with IS:516. The 28 day test strength
result for each cube shall form an item of the sample. Tests at other age shall
also be performed, if specified.

Where automated batching plant/Ready Mixed Concrete Plant is located away

from the place of use and the time gap between production and placement is
more than the initial setting time or where any ingredients are added
subsequent to mixing, separate sets of samples shall be collected and tested at
batching plant and at location of placement. The results shall be compared and
used to make suitable adjustment at batching plants so that properties of
concrete at placement are as per the requirements.

1717.5 Test Specimen and Sample Strength

Three test specimens shall be made from each sample for testing at 28 days.
Additional cubes may be required for various purposes such as to determine
the strength of concrete at 7 days or for any other purpose.

The test strength of the sample shall be the average of the strength of 3 cubes.
The individual variation should not be more than ±15 percent of the average.
If variation is more, the test results of the sample are invalid.

1717.6 Frequency

The minimum frequency of sampling of concrete of each grade shall be in

accordance with Table 1700-9.

44
 Table 1700-9 : Minimum Frequency of Sampling

Quantity of Concrete in Work, m3 No. of Samples

1—5 1
6 — 15 2
16 — 30 3
31 —50 4
51 and above 4 plus one additional sample for each additional
50 m3 or part thereof

At least one sample shall be taken from each shift of work.

1717.7 Acceptance criteria

1717.7.1 Compressive Strength

1) Cubes
The concrete shall be taken as having the specified compressive
strength when both the following conditions are met:
• The mean strength determined from any group of four
consecutive non-overlapping samples exceeds the specified
characteristic compressive strength by 3 MPa.
• Strength of any sample is not less than the specified
characteristic compressive strength minus 3 MPa.
The quantity of concrete represented by the test results
include the batches from which the first and last samples
were taken, together with all intervening batches.
2) Cores
When the concrete does not satisfy both the conditions given in (1)
above, representative cores shall be extracted from the hardened
concrete for compression test in accordance with the method
described in IS:1199 and tested to establish whether the concrete
satisfies the requirement of compressive strength.
Evaluation of compressive strength by taking cores may also be
done in case of doubt regarding the grade of concrete used either
due to poor workmanship or based on results of cube strength
tests.

The locations from which core samples are to be taken and their number shall
be decided so as to be representative of the whole of the concrete under
consideration. However, in no case shall fewer than three cores be tested.
Cores shall be prepared and tested as described in IS:516. Concrete in the
member represented by a core test shall be considered acceptable if the
45
average equivalent cube strength of the cores is equal to at least 85 percent of
the cube strength of the grade of concrete specified for the corresponding age
and no individual core has strength less than 75 percent of the specified
strength.

1717.7.2 Chloride and Sulphate Content

The total chloride and sulphuric anhydride (SO3) content of all the constituents
of concrete as a percentage of mass of cement in the mix, shall not exceed the
values given in this Section.

1717.7.3 Density of Fresh Concrete

Where minimum density of fresh concrete is specified, the mean of any four
consecutive non-overlapping samples shall not be less than the specified value
and any individual sample result shall not be less than 97.5 percent of the
specified value.

1717.7.4 Density of Hardened Concrete

Where minimum density of hardened concrete is specified, the mean of any

four consecutive non-overlapping samples shall not be less than the specified
value and any individual sample result shall not be less than 97.5 percent of
the specified value.

1717.7.5 Permeability Test

Water permeability test as per DIN:1048 Part 5-1991 shall be carried out as
described below :

i) A cylindrical test specimen 150 mm dia and 160 mm high

shall prepared.

ii) After 28 days of curing, the test will be conducted between

28 and 35 days. The test specimen shall be fitted in a
machine such that specimen can be subjected to a water
pressure of up to 7 bars. Atypical machine is shown in
Appendix-1700/1.

iii) The concrete specimen shall be subjected to a water

pressure of 0.5 N/mm2 from the top for a period of 3 days.
The pressure shall be maintained constant throughout the
test period. If the water penetrates through to the underside
of the specimen, the test may be terminated and the
specimen rejected as failed.

iv) After 3 days, the pressure shall be released and the sample
shall be taken out. The specimen shall be split in the middle
46
 by compression applied on two round bars on opposite sides
above and below.

v) When the split faces show signs of drying (after 5 to 10

minutes), the maximum depth of penetration in the direction
of height shall be measured with the scale and extent of
water penetration established.

vi) The mean of maximum depth of penetration obtained from

three specimens thus tested, shall be taken as the test result
and it shall not exceed 25 mm.
1717.7.6 If the concrete is not able to meet any of the standards of
acceptance as prescribed, the effect of such deficiency on the structure shall
be investigated by the Contractor as directed by the Engineer. The Engineer
may accept the concrete as sub-standard work. Any additional work required
by the Engineer for such acceptance, shall be carried out by the Contractor at
his cost. In case the concrete is not found to be acceptable even after
investigation, the Contractor shall remove the rejected concrete forthwith.

1717.7.7 When durability of concrete is desired the rapid chloride ion

permeability test as stated under Clause 1714.3.1 shall also be performed in
addition to above tests.

1500 FORM WORK

1501 DESCRIPTION

Formwork shall include all temporary or permanent forms required for forming
the concrete of the shape, dimensions and surface finish, as shown on the
drawing or as directed by the Engineer, together with all props, staging,
centering, scaffolding and temporary construction required for their support.

1502 MATERIALS

All materials shall comply with the requirements of IRC:87. Materials and
components used for formwork shall be examined for damage or excessive
deterioration before use/re-use and shall be used only if found suitable after
necessary repairs. In case of timber formwork, the inspection shall not only
cover physical damages but also signs of attacks by decay, rot or insect attack
or the development of splits.

Forms shall be constructed with metal or timber. The metal used for forms shall
be of such thickness that the forms remain true to shape. All bolts should be
countersunk. The use of approved internal steel ties or steel or plastic spacers
shall be permitted. Structural steel tubes used as support for forms shall have

47
a minimum wall thickness of 4 mm. Other materials conforming to the
requirements of IRC:87 may also be used if approved by the Engineer.

1503 DESIGN OF FORMWORK

1503.1 The design, erection and removal of formwork shall conform to

IRC:87 "Guidelines for Formwork, Falsework and Temporary Structures" and
these specifications. The forms shall be such as to ensure that they can be
conveniently removed without disturbing the concrete. The design shall
facilitate proper and safe access to all parts of formwork for inspection.

1503.2 The Contractor shall furnish the design and drawing of complete
formwork (i.e. the forms as well as their supports) for approval of the Engineer
before any erection is taken up. If proprietary system of formwork is used, the
Contractor shall furnish detailed information as per Appendix 1500/I, to the
Engineer for approval.

Notwithstanding any approval or review of drawing and design by the Engineer,

the Contractor shall be entirely responsible for the adequacy and safety of
formwork.

1503.3 In the case of prestressed concrete superstructure, careful

consideration shall be given to redistribution of loads on props due to
prestressing.

1504 WORKMANSHIP

1504.1 The formwork shall be robust and strong and the joints shall be
leak-proof. Ballies shall not be used as staging. Staging must have cross
bracings and diagonal bracings in both directions. Staging shall be provided
with an appropriately designed base plate resting on firm strata.

1504.2 The number of joints in the formwork shall be kept to a minimum

by using large sized panels. The design shall provide for proper "soldiers" to
facilitate alignment. All joints shall be leak proof and must be properly sealed.
Use of PVC joint sealing tapes, foam rubber or PVC T-section, is essential to
prevent leakage of grout.

1504.3 As far as practicable, clamps shall be used to hold the forms

together. Where use of nails is unavoidable, minimum number of nails shall be
used and these shall be of the double-headed type. Alternatively, if the nails
are of the normal type, they shall be left partially projecting without being
driven to their full length, so that they can be withdrawn easily.

48
1504.4 Use of ties shall be restricted, as far as practicable. Wherever ties
are used they shall be used with HDPE sheathing so that they can easily be
removed. No parts prone to corrosion shall be left projecting or near the
surface. The sheathing shall be grouted with cement mortar of the same
strength as that of the structure.

1504.5 Unless otherwise specified, or directed, chamfers or fillets of size

25 mm x 25 mm shall be provided at all angles of the formwork to avoid sharp
corners. The chamfers, beveled edges and mouldings shall be made in the
formwork itself. Opening for fixtures and other fittings shall be provided in the
shuttering as directed by the Engineer.

1504.6 Shuttering for walls, sloping members and thin sections of

considerable height shall be provided with temporary openings to permit
inspection and cleaning out before placing of concrete.

1504.7 The formwork shall be constructed with pre-camber to the soffit

to allow for deflection of the formwork. This shall be in addition to the pre-
camber for the permanent structure as shown on the drawings.

1504.8 Where centering trusses or launching trusses are adopted for

casting of superstructure, the joints of the centering trusses, whether welded,
riveted or bolted shall be thoroughly checked periodically. Also, various
members of the centering trusses should be periodically examined for proper
alignment and unintended deformation before proceeding with the concreting.
They shall also be periodically checked for any deterioration in quality due to
steel corrosion. Launching truss, casting truss of span more than 40 m and
travelling forms, shall be load tested before they are put to use.

1504.9 The formwork shall be so made as to produce a finished

concrete true to shape, line and levels and dimensions as shown on the
drawings, subject to the tolerances specified in respective Sections of these
specifications, or as directed by the Engineer.

1504.10 Where metal forms are used, all bolts and rivets shall be
countersunk and well ground to provide a smooth, plane surface. Where timber
is used it shall be well seasoned, free from loose knots, projecting nails, splits
or other defects that may mar the surface of concrete.

1504.11 Forms shall be made sufficiently rigid by the use of ties and
bracings to prevent any displacement or sagging between supports. They shall
49
be strong enough to withstand all pressure, ramming and vibration during and
after placing the concrete. Screw jacks or hard wood wedges where required
shall be provided to make up any settlement in the formwork either before or
during the placing of concrete.

1504.12 The formwork shall ensure the correct final shape of the
structure, with the calculated amount of positive or negative camber. The
deformation of falsework, scaffolding or propping and the instantaneous or
deferred deformation due to various causes arising in prestressed structures,
shall be properly accounted for.

1504.13 Suitable camber shall be provided to horizontal members of

structure, specially in long spans, to counteract the effects of deflection. The
formwork shall be so fixed as to provide for such camber.

1504.14 The formwork shall be coated with an approved release agent

that will effectively prevent sticking and will not stain the concrete surface.
Lubricating oils (machine oils) shall be prohibited for use as coating.

1505 LINING OF FORMWORK

The formwork shall be lined with material approved by the Engineer so as to

provide a smooth finish of uniform texture and appearance. This material shall
leave no stain on the concrete and shall be so fixed to its backing as not to
impart any blemishes. It shall be of the same type and obtained from only one
source throughout for the construction of any one structure. The contractor
shall make good any imperfections in the resulting finish as required by the
Engineer. Internal ties and embedded metal parts shall be carefully detailed
and their use shall be subject to the approval of the Engineer.

1506 PRECAUTIONS

The following precautions shall be observed:

i) It shall be ensured that any cut-outs or openings provided in any

structural member to facilitate erection of formwork, are closed
with the same grade of concrete as that of the structure, after
formwork is removed.

ii) Provision for safe access to the formwork shall be made at all levels
as required.

iii) Close watch shall be maintained to check for settlement of

formwork during concreting and any settlement shall be promptly
rectified.
50
 iv) Natural ground shall be checked for bearing capacity and likely
settlement before erection of the staging.

v) it shall be ensured that water used for curing or rain water does
not stagnate near the base plate of the staging.

vi) For shutters used for deep and narrow member, temporary
openings in the sides shall be provided to facilitate pouring and
compaction of concrete.

1507 PREPARATION OF FORMWORK BEFORE CONCRETING

The inside surfaces of forms shall, except in the case of permanent formwork
or where otherwise agreed to by the Engineer, be coated with a release agent
supplied by approved manufacturer or of an approved material to prevent
adhesion of concrete to the formwork. Release agents shall be applied strictly
in accordance with the manufacturer's instructions and shall not be allowed to
come in contact with any reinforcement or prestressing tendons and
anchorages. Different release agents shall not be used in formwork for exposed
concrete.

Before re-use of forms, the following actions shall be taken :

i) The contact surfaces of the forms shall be cleaned carefully

and dried before applying a release agent.

ii) It should be ensured that the release agent is appropriate to the

surface to be coated. The same type and make of release agent
shall be used throughout on similar formwork materials and
different types should not be mixed.

iii) The form surfaces shall be evenly and thinly coated with release
agent. The vertical surface shall be treated before horizontal
surface and any excess wiped out.

iv) It shall be ensured that the reinforcement or the surface of the

hardened concrete shall not come in contact with the release
agent.

v) All forms shall be thoroughly cleaned immediately before

concreting.

The Contractor shall give the Engineer due notice before placing any concrete
in the forms to permit him to inspect and approve the formwork. However, such
inspection shall not relieve the contractor of his responsibility for safety of
formwork, men, machinery, materials and finish or tolerances of concrete.
51
1508 REMOVAL OF FORMWORK

The scheme for removal of formwork (Le. de-shuttering and de-centering)

shall be planned in advance and furnished to the Engineer for scrutiny and
approval. No formwork or any part thereof shall be removed without prior
approval of the Engineer.

The formwork shall be so removed a s not to cause any damage to concrete.

Centering shall be gradually and uniformly lowered in such a manner as to
permit the concrete to take stresses due to its own weight uniformly and
gradually to avoid any shock or vibration.

Form work shall not be released unless the concrete has achieved strength of
at least twice the stress the concrete may be subjected at the time of the
removal of formwork. When no test is conducted for determination of strength
of concrete and where the time of removal of formwork is not specified, the
same shall be as under :
a) Walls, piers, abutments, columns and 12 to 48 hours as may be
vertical faces of structural members decided by the Engineer
b) Soffits of Slabs (with props left under) 3 days
c) Props left under slabs 14 days
d) Soffits of Girders (with props left under) 7 days
e) Props (left under girders) 21 days

The above time schedule is applicable when ordinary Portland Cement is used
without any admixtures at an ambient temperature exceeding 10°C.

For concrete made with Portland pozzolona cement, Portland slag cement or
mineral admixtures, additional cube samples shall be taken for verifying the
strength of concrete to decide the time of deshuttering.

Where there are re-entrant angles in the concrete sections, the formwork
should be removed at these sections as soon as possible after the concrete has
set, in order to avoid cracking due to shrinkage of concrete.

Additional precautions as given in Clause 8.17 of IRC: 87, shall also be followed.

1509 RE-USE OF FORMWORK

When the formwork is dismantled, its individual components shall be examined

for damage and damaged pieces shall be removed for rectification. Such
examination shall always be carried out before their use again. Before re-use
all components shall be cleaned of deposits of soil, concrete or other unwanted
materials. Threaded parts shall be oiled after cleaning.

52
All bent steel props shall be straightened before re-use. The maximum
permissible deviation from straightness is 1/600 of the length. The maximum
permissible axial loads in used props shall be suitably reduced depending upon
their condition. The condition of the timber components, plywood and steel
shuttering plates shall be examined closely for distortion and defects before re-
use.

1510 SPECIALISED FORMWORK

Specialised formwork such as slipform, floating caisson and travelling form,

wherever used shall be designed and detailed by competent agencies and a set
of complete working drawings and installation instructions supplied to the
Engineer. In case proprietary equipment is used, the supplier shall furnish
drawings, details, installation instructions etc, in the form of manuals along with
the formwork.

For slipform, the rate of climb of the formwork shall be designed for each
individual case taking into account various parameters including the grade of
concrete, concrete strength, concrete temperature, ambient temperature and
concrete admixtures.

For floating caisson, the details of fabrication, floating to site and placing in
position shall be as given in Clause 1203.5 of these Specifications.

In order to verify the time and sequence of striking/removal of specialized

formwork, routine field tests for the consistency and strength development of
concrete are mandatory.

For specialized formwork, the form lining material may be either plywood or
steel sheet of appropriate thickness.

1511 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.

1718 MEASUREMENTS FOR PAYMENT

Structural concrete shall be measured in cubic meters basis with finished

work. In reinforced or prestressed concrete, the volume occupied by
reinforcement or prestressing cables and sheathing shall not be deducted. The
slab shall be measured as running continuously through and the beam as the
portion below the slab.

53
1719 RATE

The contract unit rate for structural concrete shall cover costs of all materials,
labour, tools, plant and equipment required for mixing, transporting and placing
in position, vibrating and compacting, finishing and curing as per this Section
or as directed by the Engineer, including all incidental expenses, sampling and
testing, quality assurance and supervision. Unless mentioned separately as an
item in the contract, the contract unit rate for concrete shall also include the
cost of providing, fixing and removing formwork required for concrete work as
per Section 1500 of these Specifications.

If the concrete is found to be acceptable by the Engineer as sub-standard work,

the Contractor shall be subjected to reduction in his contact unit rate. For
deficiency in compressive strength of concrete when accepted by the Engineer,
the reduction in rate shall be applied as under:

Design Strength Observed Strength

Percentage reduction in rate = x 100
Design Strength

Item No.6: - Providing and casting in situ controlled cement concrete

M-30 for R.C.C. Wall as per drawings including centering huttering,
scaffolding where necessary, laying vibrating, curing and finishing
complete.

This work shall consist of Providing and casting in situ controlled cement with
of M-30 for R.C.C. Wall as per drawing including centering shuttering
scaffolding where necessary laying vibrating curing and finishing complete. It
shall be carried out as per relevant detailed specification of Item No. 5 of this
contract.

The item shall be measured & paid as finished work in cubic meter.

Item No.7: - Providing & laying weep hole in Abutments, and returns
by using A.C. pipe of 100mm including laying in proper grade and
jointing the completed as per detailed specification.

Weep holes shall be provided in solid plain concrete/reinforced concrete,

brick/stone masonry, abutment, wing wall and return walls as show. on the
drawing or directed by the Engineer to drive moisture from the back filling.
Weep holes shall be provided with 100 mm dia P.V.C. pipe for structures in
plain/reinforced concrete or brick masonry. In case of stone masonry, weep
holes shall be 80 mm wide, 150 mm high or circular with 150mm diameter.

54
Weep holes shall extend through the full width of concrete/masonry with slope
of about 1 vertical:20 horizontal towards the draining face. The spacing of weep
holes shall generally be 1m in either direction or as shown in the drawing with
the lowest at about 150 mm above the low water level or ground level
whichever is higher or as directed by the Engineer.
Weep holes in concrete/brick masonry structure shall be measured in
numbers.
The contract unit rate for weep hole shall include the cost of all labour.
Item No.8: - Providing and casting in situ controlled cement concrete
of M 30 wearing coat laid as directed including tamping vibrating
finishing curing and filling in joints with bitumen complete.

Cement Concrete Wearing Coat

Cement concrete wearing coat shall be laid separately over the bridge deck.
The thickness of wearing coat shall be 75 mm or as per drawing. The concrete
shall be of minimum M 30 grade. In a length of 1 m near the expansion joint
additional reinforcement of 8 mm diameter bars shall be provided in both
directions to make the spacing as 75 mm.

Cement concrete and steel reinforcement shall conform to Section 1700 and
Section 1600 respectively of these Specifications.

Curing of wearing coat shall start as early as possible.

All carriageway and footpath surfaces shall have non-skid characteristics.

This work shall consist of providing and casting in situ-controlled cement

concrete M 30 grade for Wearing coat and shall be carried out as per relevant
detailed specification of Item No. 5 of this contract. The item shall be
measured & paid as finished work in cubic meters.

Item No.9: - Providing and fixing in position Fe-500D (T.M.T)

reinforcement including cutting, bending, hooking, tying and welding
complete and including forming the cage and lowering it in position.

1601. GENERAL
This work shall consist of furnishing and placing T.M.T. reinforcement bars
(intentioned) of the shape and dimensions shown on the drawings and
conforming to these Specifications or as approved by the Engineer in charge.
1602. MATERIAL
1602.1. T.M.T. Bars

55
For Reinforced cement Concrete, the reinforcement steel as the case may be,
shall consist of the following grade of reinforcing bars.

Table 1000-3 Grades of Reinforcing Bar

Grade Bar Type Confirming Governing IS Elastic

Designation Specifications Characteristics Modules
Strength fy GP
Mpa
Fe 240 IS: 432 part I Mild Steel 240 200
Fe 415 IS: 1786 High Strength Deformed steel 415 200
Bar (HSD)
Fe 500 or IS: 1786 High Strength Deformed steel 500 200
Fe 500D Bar (HSD)
Fe 550 or IS: 1786 High Strength Deformed steel 550 200
Fe 550D Bar (HSD)
Fe 600 IS: 1786 High Strength Deformed steel 600 200
Bar (HSD)

All steel shall be produced from ‘original procedure’ who manufactures billets
directly from iron ores and roll the billets to produced steel confirming to
IS:1786 no re-rolled steel shall be incorporate in the works. However, in case
the original producer give certificate that they are not producing bars of the
required diameter, the engineer may allow the procurement of steel from other
suppliers, provided that the reinforcement is manufactured from billets
produced from original producers. In such cases, the manufacture’s certificate
alone shall not be considered as sufficient and the steel shall be got tested by
the engineer in the NABL accredited laboratories only, as a third-party check.
It shall be ensured that all the test result shall be confirmed to IS: 1786
requirements.

Only new steel shall be delivered to the site. Every bar shall be inspected before
placing to its position and defective brittle or burnt bar shall be discarded. Bar
with cracked ends of bars shall be discarded.

For the steel procured from original producers also, the Engineer/ Employer
may carry out occasional checks on materials through third party as mentioned
above, for confirming the test results shown in the certificates, in case of any
doubt regarding the quality of steel supplied.

3.0. Pitch
3.1. Distance between bars shall be as specified in drawings and as directed
by the Engineer in Charge all bars shall be placed at an accurate distance from
each other and shall be bind tightly to maintain the desired pitch Suitable means
shall be provided for holding bars securely in position

56
4.0. Binding wire
4.1. Mild steel binding wire shall be of 1.63 mm or 1.22 mm (16 to 18-gauge
diameter and shall conform IS 280-1972

4.2. The use of black wire will be permitted for binding reinforcement bars. It
shall be free form free from dirt, paint, grease or oil, oil scale or loose or thick
rust and any other undesirable coating which may prevent adhesion of cement
mortar at the time of binding

4.3. Only new binding wire shall be delivered to the site all binding wire shall
be inspected before binding to its position and defective brittle, rusted, used
wire, shall be discarded

1603 PROTECTION OF REINFORCEMENT

Uncoated reinforcing steel shall be protected from rusting or chloride
contamination. Reinforcements shall be free from rust, mortar, loose mill scale,
grease, oil or paints. This may be ensured either by using reinforcement fresh
from the factory or thoroughly cleaning all reinforcement to remove rust using
any suitable method such as sand blasting, mechanical wire brushing, etc. as
directed by the Engineer. Reinforcements shall be stored on bricks, racks or
platforms and above the ground in a clean and dry condition and shall be
suitably marked to facilitate inspection and identification.

Portions of uncoated reinforcing steel and dowels projecting from concrete shall
be protected within one week after initial placing of concrete with a brush coat
of neat cement mixed with water to a consistency, of thick paint. This coating
shall be removed by lightly tapping with a hammer or other tool not more than
one week before placing of the adjacent pour of concrete. Coated reinforcing
steel shall be protected against damage to the coating. If the coating on the
bars is damaged during transportation or handling and cannot be repaired, the
same shall be rejected.

1604 BENDING OF REINFORCEMENT

Bar bending schedule shall be furnished by the Contractor and got approved by
the Engineer before start of work.
Reinforcing steel shall conform to the dimensions and shapes given in the
approved bar bending Schedules.

Bars shall be bent cold to the specified shape and dimensions or directed by
the Engineer using a proper bar bender operated by hand power to obtain the
correct radius of bends and shape.
Bars shall not be bent or straightened in a manner that will damage parent
material or the coating.

57
Bars bent during transport or handling shall, be straightened before being used
on work and shall not be heated to facilitate straightening.

1605 PLACING OF REINFORCEMENT

a) The reinforcement cage should generally be fabricated in the yard at ground
level, and then shifted and placed in position. The reinforcement shall be placed
strictly, in accordance with the drawings and shall be assembled in position,
only when structure is otherwise ready for placing of concrete. Prolonged time
gap, between assembling of reinforcements and casting of concrete, which may
result in rust formation on the surface, shall not be permitted.

b) Reinforcement bars shall be placed accurately in position as shown on the

drawings. The bars, crossing one another shall be tied together at every
intersection with binding wire (annealed), conforming to IS:280 to make the
skeleton of the reinforcement rigid such that the reinforcement does not get
displaced during placing of concrete, or any other operation. The diameter of
binding wire shall not be less than 1 mm.

c) Bars shall be kept in position usually by the following methods:

i) In case of beam and slab construction, industrially produced polymer cover

blocks of thickness equal to the specified cover shall be placed between
the bars and formwork subject to Satisfactory evidence that the polymer
composition is not harmful to concrete and reinforcement. Cover blocks
made of concrete may be permitted by the Engineer, provided they have
the same strength and specification as those of the member.

ii) In case of dowels for pier and walls the vertical reinforcement shall be
kept in position by means of timber templates with slots in them
accurately, or with cover blocks tied to the Reinforcement Timber
templates shall be removed after the concreting has progressed up to a
level just below their location.

iii) Layers of reinforcements shall be separated by spacer bars at

approximately One-meter intervals. The minimum diameter of spacer bars
shall be 12 mm or: equal to maximum size of main reinforcement or
maximum size of coarse aggregate, whichever is greater. Horizontal
reinforcement shall not be, allowed to sag between supports.
iv) Necessary stays, blocks, metal chairs, spacers, metal hangers supporting
wires etc, or other subsidiary, reinforcement shall be provided to fix the
reinforcements firmly in its correct position.
v) Use of pebbles, broken stone, metal pipe, brick, mortar or wooden blocks
etc as devices for positioning reinforcement shall not be permitted.
d) Bars coated with epoxy or any other approved protective coating shall be
placed on supports that do not damage the coating. Supports shall be installed
58
in a manner such that planes of weakness are not created in hardened
concrete. The coated reinforcing steel shall be held in place by use of plastic or
plastic-coated binding wires especially manufactured for the purpose. Refer
Section 1000 of these Specifications for other requirements.
e) Placing and fixing of reinforcement shall be inspected and approved by the
Engineer before concrete is deposited.

1606 BAR SPLICES

1606.1 Lapping
All reinforcement shall be furnished in full lengths as indicated on the drawing.
No splicing of bars, except where shown on the drawing; will be permitted
without approval of the Engineer. The lengths of the splice shall be as indicated
on drawing or as approved by the Engineer. Where practicable, overlapping
bars shall not touch each other and shall be kept apart by 25 mm or 11 1/4
times the maximum size of coarse aggregate, whichever is greater, If this is
not feasible, overlapping bars shall be bound with annealed steel binding wire,
not less than 1 mm diameter and twisted tight in such a manner as to maintain
minimum clear cover to the reinforcement from the concrete surface. Lapped
splices shall be staggered or located at points, along the span where stresses
are low.

1606.2 Welding

1606.2.1 Splicing by welding of reinforcement will be permitted only if

detailed on the drawing or approved by the Engineer. Weld shall develop an
ultimate strength equal to or greater than that of the bars connected.
1606.2.2 While welding may be permitted for H.Y.S.D. reinforcing bars
conforming to IS:432, welding of deformed bars conforming to IS: 1786 shall
in general be prohibited. Welding may be permitted in case of bars of other
than S 240 grade including special. Welding grade of S 415 grade bars
conforming to IS:1786, for which necessary chemical analysis has been secured
and the carbon equivalent (CE) calculated from the chemical composition using
the formula:

CE = C + Mn + Cr + Mg + V + Ni + Cu
6 5 15
is 0.4 or less.
1606.2.3 The method of welding shall conform to IS:2751 and IS:9417 and
to any supplemental and clause 1904.8 of these specifications to the
satisfaction of the Engineer.

Welding may be carried out by metal arc welding process. Oxy-acetelene

welding shall not be permissible. Any other process may be used subject to the

59
approval of the Engineer and necessary additional requirements to ensure
satisfactory joint performance. Precautions on over heating, choice of
electrode, selection of correct current in arc welding etc., should be strictly
observed.

All bars shall be butt welded except for smaller diameter bars (diameter of less
than 20 mm) which may be lap welded. Single-V or Double-V bun joints may
generally be used. For vertical bars single bevel or double bevel joints may be
used.

Welded joints shall be located well away from bends and not less than twice
the bar diameter away from a bend.

Generally, shop welding in controlled conditions is to be preferred, where

feasible. Site welding where necessary shall, however, be permitted when the
facilities, equipment, process, consumables, operators, welding procedure are
adequate to produce and maintain uniform quality at par with that attainable
in shop welding to the satisfaction of the Engineer.

Joint welding procedures which are to be employed shall invariably be

established by a procedure specification. All welders and welding operators to
be employed shall have to be qualified by tests prescribed in IS:2751.
Inspection of welds shall conform to IS:822 and destructive or non-destructive
testing may be undertaken when deemed necessary. Joints with weld defects
detected by visual inspection or dimensional check inspection shall not be
accepted.

Suitable means shall be provided for holding the bars securely in position during
welding. It must be ensured that no voids are left in welding. When welding is
done in 2 or 3 stages, previous surface shall be cleaned properly. Bars shall be
cleaned of all loose scale, rust, grease, paint and other foreign matter before
carrying out welding. Oily competent and experienced welders shall be
employed on the work with the approval of the Engineer. No welding shall be
done on coated bars.

M.S. electrodes used for welding shall conform to IS:814.

1606.2.4. Welded joints shall preferably be located at points where steel will
not be subject to more than 75 per cent of the maximum permissible stresses
and welds so staggered that at any one section, not more than 20 per cent of
the bars are welded.

60
1606.2.5. Welded pieces of reinforcement shall be tested. Specimens shall be
taken from the site and the number and frequency of tests shall be as directed
by the Engineer.

1606.3. MECHANICAL COUPLERS AND ANCHORAGES

1606.3.1 MECHANICAL COUPLERS

Bars may be joined with approved patented mechanical devices as indicated on

the drawing or as approved by the Engineer e.g. by special grade steel sleeves
swaged on to bars in end to end contact or by screwed couplers. In case such
devices are permitted by the Engineer, they shall develop at least 125 per cent
of the characteristic strength of the reinforcement bar.

1606.3.2 ANCHORAGES

Bars may be anchored with approved patented mechanical anchorages as

indicated on the drawing or as approved by the Engineer. The anchorages shall
be connected to the reinforcing bar by the use of taper thread system. The
anchorages shall be capable of developing the characteristics strength of
reinforcement without damage to concrete and shall have sufficient diameter
and width to develop adequate shear cone strength. The connection shall
develop 125% of the characteristic’s strength of reinforcement bar.

1607. TESTING AND ACCEPTANCE

The material shall be tested in accordance with relevant IS specifications and

necessary test certificates shall be furnished. Additional tests, if required, will
be got carried out by the Contractor at his own cost.
The supply, fabrication, furnishing and placing of reinforcement shall be in
accordance with these specifications and shall be checked and accepted, by the
Engineer.
Manufacturer’s test certificate regarding compliance with Indian Standards for
each lot of steel, shall be obtained and confirmatory tests in the presence of a
person authorized by the Engineer. Cost of these tests shall be borne by the
Contractor. The sampling and testing procedure shall be as laid down is IS:
1786. If any test piece selected from a lot fails, no re-testing shall be done and
the lot shall be rejected.

1608. MEASUREMENTS FOR PAYMENT

Reinforcement shall be measured in length including hooks, if any, separately

for different diameters as actually used in work, excluding overlaps. From the
61
length so measured, the weight of reinforcement shall be calculated in Metric
tonne basis of IS:1732. Wastage, overlaps, couplings: welded joints, spacer
bars, chairs, stays, hangers and annealed steel wire or other methods for
binding and placing shall not be measured and cost of these items shall be
deemed to be included in. the rates for reinforcement.

1609. RATE
The contract unit rate for coated reinforcement shall cover the cost of material,
fabricating, transporting, storing, bending, placing, binding and fixing in
position as shown on the drawings as per these specifications and as directed
by the Engineer, including all labour, equipment, supplies, incidentals,
sampling, testing and supervision.
The unit rate for coated reinforcement shall be deemed to also include cost of
all material, labour, tools and plant, royalty, transportation and expertise
required to carry out the coating work as well as sampling, testing and
supervision required for the work.

Item No.10: - Provision of an Reinforced cement concrete crash

barrier at the edges of the road, approaches to bridge structures and
medians, constructed with M-40 grade concrete with Fe-500D
reinforcement conforming to IRC:21 and dowel bars 25 mm dia., 450
mm long at expansion joints filled with pre-moulded asphalt filler
board, keyed to the structure on which it is built and installed as per
design given in the enclosure to MOST circular No. RW/NH -
33022/1/94-DO III dated 24 June 1994 as per dimensions in the
approved drawing and at locations directed by the Engineer, all as
specified as per drawing attached.

This work shall consist of providing and casting in situ-controlled cement

concrete M 40 grade for Crash Barrier shall be carried out as per relevant
detailed specification of Item No. 5 of this contract and Steel shall be as per
Item No.9.
Cast In-Situ Concrete Crash Barrier

The portion of the railing/crash barrier or parapet which is to be cast in-situ shall
be constructed in accordance with the requirements for Structural Concrete
Section and reinforcement conforming to Sections 1600 and 1700 of these
Specifications.

Forms shall be fabricated conforming to the shape of crash barrier shown on

the drawings. It shall be ensured that no form joint appears on plane surfaces.

62
For bridges/ viaducts of length more than 500 m horizontal slip forms shall be
used for casting of crash barriers.

All moldings, panel work and bevel strips shall be constructed according to the
details shown on the drawings. All corners in the finished work shall be true,
sharp and clean-cut and shall be free from cracks, spalls or other defects.
Castings of posts shall be done in single pour.

Grade of concrete will be M-40. All above material shall be used as per complete
working drawing and sanctioned by engineer in charge.
The item shall be measured & paid as finished work in Running meters.
Item No.11: - Providing G.I. 100 mm. diameter water spouts including
necessary iron gratings as per drawings.

This work shall consist of furnishing and fixing in position of drainage spouts
and drainage pipes for bridge decks.
2705 Drainage along longitudinal direction shall be ensured by sufficient
number of drainage fixtures embedded in the deck slab. The spouts shall be of
not less than 100 mm in diameter and shall be corrosive resistant material such
as galvanized steel with suitable cleanout fixtures. The spacing of drainage
spouts shall not exceed 10 m. The discharge from drainage spout shall be kept
away from the deck structure by means of suitable down pipes upto 500 mm
above High Flood Level. In case of viaducts in urban areas, the drainage spouts
should be connected with suitably located runners and down pipes to discharge
the surface run-off to drains provided at ground level.

2705.1. Fabrication
The drainage assembly shall be fabricated to the dimensions shown on the
drawings. All materials shall be corrosion resistant; Steel components shall be
of mild steel conforming to 18:226. The drainage assembly shall be seam
welded for water tightness and then hot-dip galvanized.

2705.2. Placement
The galvanized assembly shall be given two coats of bituminous paint before
placement. The whole assembly shall be placed in true position, lines and levels
as shown in the drawing with necessary cutouts in the shuttering for deck slab
and held in place firmly. Where the reinforcements of the deck are required to
be cut, equivalent reinforcements shall be placed at the corners of the cut out.

63
2705.3. Finishing
After setting of the deck slab concrete, the shrinkage cracks around the
assembly shall be sealed with polysulphide sealant or bituminous sealant as per
IS: 1834 and the excess sealant trimmed to receive the wearing coat After the
wearing coat is completed, similar sealant shall be provided to cover at least
50 mm on the wearing coat surface all-round the drainage assembly.

Drainage spouts shall be measured in Numbers.

The contract unit rate for each drainage spout shall include the cost of
all labour, material, tools and plant required for completing the work as per
these Specifications. It shall also include the cost of providing flow drain pipes
with all fixtures up to the point of ground drains wherever shown on the
drawings.

Item No.12: - Providing and laying Filter Media 600mm Thick directed
at the back of Abutment, return and wing walls as per detailed
specification.

1. Well graded pebbled or metal of 40 mm. to 63 mm. size shall be used,

the grading and tolerances of metal of pebbles shall be as under:-
Sr. No. of Size Range Sieve designation Percentage by wight
No. passing through the sieve
1. 63 mm to 40 mm 90 mm 100-00
63 mm 85-100
50 mm 35-70
40 mm 00-15
20 mm 00-05
The size shall be 40 mm. to 63 mm. where in tolerance limit for
over size shall be upto 15% and that for lower size should be upto 15% and
below 20 mm. it shall be allowable upto 5%. The filter Material shall be tightly
placed to a thickness of not less that 600 mm. and provided over the entire
surface behind abutments, wings or return walls to the full height as shown on
drawing and as directed.
2. Materials shall be first stacked in box of 2 m. x 1.½ m. x 0.5 m. size on
fairly level ground and measured for cross checking the adequacy of the
quantity required.

64
3. The filter media behind abutment and return wall shall consist of three
layers, the first layer of rubble of required size, the second layer of stone
aggregates of 40 to 63 mm size and the third layer of coarse sand. The total
thickness of the filter media shall not be less than 600mm as specified in the
item.
4. The measurement for payment shall be made as finished work on Sq.m.
basis
5. The unit rate includes the cost of materials, scaffolding labour and tools
to complete the work.
Item No.13: - Filling available excavated earth/weathered rock in
trenches, sides of foundations etc. in layers not exceeding 20 cm in
depth consolidating each deposited layer by ramming and watering.

1.0 WORKMANSHIP

1.1. The earth to be used for filling shall be free from salts, organic or other
foreign matter all clots of earth shall be broken.

1.2. As soon as the work in foundation has been completed and measured
the site of foundation shall be cleared of all debris brick bats mortar
dropping etc. and filled with earth in layers not exceeding 20 cms. each
layer shall be adequately watered, rammed and consolidated before the
succeeding layer is laid. The earth shall be rammed with iron rammers
where feasible and with the ends of crow-bars, where rammer cannot be
used.

1.3 The foundation shall be similarly filled with earth in layers not exceeding
20 cms adequately watered and consolidated by ramming with iron or
wooden rammers. When filling reaches finished level the surface shall be
flooded with water for at least 24 hours and allowed to dry and then
rammed and consolidated.

1.4 The finished level of filling shall be kept to shape intended to be given to
shape.

65
1.5 In case of large area the consolidation may be done by power rollers,
where so specified. The extent of consolidation required shall also be as
specified.
2.0. Mode of Measurements & Payment
2.1. The payment shall be made for filling in plinth and trenches. No
deduction shall be made for shrinkage or voids, if consolidated as
instructed above.
2.2. The rate shall be for a unit of one cubic meter.
Item No.14: - Clearing and grubbing road land including uprooting
rank vegetation , grass , bushes , shrubs , saplings and trees of girth
Upto 300 mm removal of stumps of trees cut earlier and disposal of
unserviceable materials (I) By Mechanical means in area of light
jungle.

201.1 Scope
This work shall consist of cutting, removing and disposing of all materials such
as trees, bushes, shrubs, stumps, roots, grass, weeds, rubbish, top organic soil,
etc. to an average depth of 150 mm in thickness, which in the opinion of the
Engineer are unsuitable for incorporation in the works, from the area of road
land containing road embankment, drains, cross-drainage structures and such
other areas as may be specified on the drawings or by the Engineer. It shall
include necessary excavation, backfilling of pits resulting from uprooting of
trees and stumps to required compaction, handling, salvaging, and disposal of
cleared materials with all leads and lifts. Clearing and grubbing shall be
performed in advance of earthwork operations and in accordance with the
requirements of these Specifications.

201.2 Preservation of Property/Amenities

Roadside trees, shrubs, any other plants, pole lines, fences, signs, monuments,
buildings, pipelines, sewers and all highway facilities within or adjacent to the
highway which are not to be disturbed shall be protected from injury or
damage. The Contractor shall provide and install at his own cost, suitable
safeguards approved by the Engineer for this purpose. During clearing and
grubbing, the Contractor shall take all adequate precautions against soil
erosion, water pollution, etc., and where required, undertake additional works
to that effect vide Clause 306. Before start of operations, the Contractor shall
submit to the Engineer for approval, his work plan including the procedure to
be followed for disposal of waste materials, etc., and the schedules for carrying
out temporary and permanent erosion control works as stipulated in Clause
306.3.

66
201.3 Methods, Tools and Equipment
Only such methods, tools and equipment as are approved by the Engineer and
which will not affect any 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 bottom of the
subgrade. Also, all vegetation such as roots, under-growth, grass and other
deleterious matter unsuitable for incorporation in the embankment/subgrade
shall be removed between fill lines to the satisfaction of the Engineer. All
branches of trees extending above the roadway shall be trimmed as directed
by the Engineer.

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

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

201.4 Disposal of Materials

All materials arising from clearing and grubbing operations shall be taken over
and shall be disposed of by the Contractor at suitable disposal sites with all
leads and lifts. The disposal shall be in accordance with local, State and Central
regulations.

201.5 Measurements for Payment

Clearing and grubbing for road embankment, drains and cross-drainage
structures shall be measured on area basis in terms of hectares. Cutting of
trees upto 300 mm in girth and removal of their stumps, including removal of
stumps upto 300 mm in girth left over after trees have been cut by any other
agency, and trimming of branches of trees extending above the roadway and
backfilling to the required compaction shall be considered incidental to the
clearing and grubbing operations. Clearing and grubbing of borrow areas shall
be deemed to be a part of works preparatory to embankment construction and
shall be deemed to have been included in the rates quoted for the embankment
construction item and no separate payment shall be made for the same.

Ground levels shall be taken prior to and after clearing and grubbing. Levels
taken prior to clearing and grubbing shall be the base level and will be
accordingly used for assessing the depth of clearing and grubbing and
computation of quantity of any unsuitable material which is required to be

67
removed. The levels taken subsequent to clearing and grubbing shall be the
base level for computation of earthwork for embankment.

Cutting of trees, excluding removal of stumps and roots of trees of girth above
300 mm shall be measured in terms of number according to the girth 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

Removal of stumps and roots including backfilling with suitable material to

required compaction shall be a separate item and shall be measured in terms
of number according to the sizes given below: -
i) Above 300 mm to 600 mm
ii) Above 600 mm to 900 mm
iii) Above 900 mm to 1800 mm
iv) Above 1800 mm

For the purpose of cutting of trees and removal of roots and stumps, the girth
shall be
measured at a height of 1 m above ground or at the top of the stump if the
height of the stump is less than one metre from the ground.

201.6 Rates
201.6.1 The Contract unit rates for the various items of clearing and grubbing
shall be payment in full for carrying out the required operations including full
compensation for all labor, materials, tools, equipment and incidentals
necessary to complete the work. These will also include removal of stumps of
trees less than 300 mm girth excavation and backfilling to required density,
where necessary, and handling, giving credit towards salvage value disposing
of the cleared materials with all lifts and leads. Clearing and grubbing done in
excess of 150 mm by the Contractor shall be made good by the Contractor at
his own cost as per Clause 301.3.3 to the satisfaction of the Engineer prior to
taking up earthwork. Where clearing and grubbing is to be done to a level
beyond 150 mm, due to site considerations, as directed by the Engineer, the
extra quantity shall be measured and paid separately.

201.6.2 The Contract unit rate for cutting trees of girth above 300 mm shall
include handling, giving credit towards salvage value disposing of the cleared
materials with all lifts and leads.

201.6.3 The Contract unit rate for removal of stumps and roots of trees girth
above 300 mm shall include excavation and backfilling with suitable material to
required compaction, handling, giving credit towards salvage value disposing
of the cleared materials with all lifts and leads.
68
201.6.4 The Contract unit rate is deemed to include credit towards value of
usable materials, salvage value of unusable materials and off-set price of cut
trees and stumps belonging to the Forest Department. The off-set price of cut
trees and stumps belonging to the Forest Department shall be deducted from
the amount due to the Contractor and deposited with the State Forest
Department. In case the cut trees and stumps are required to be deposited
with the Forest Department the Contractor shall do so and no deduction
towards the off-set price shall be effected. The offset price shall be as per
guidelines I estimates of the State Forest Department.

201.6.5 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.

Item No.15 : - Box cutting the road surface to proper slope and
camber for making a base for road work including removing the
excavated stuff and depositing on the road side slope as directed upto
50Mt.lead.

1.This work shall consist of excavation, removal and satisfactory disposal of all
materials necessary for the construction of widening carriageway in accordance
with requirements of these specifications and the lines, grades and cross
sections shown in the drawings or as indicated by the Engineer.

2.After the site has been cleared the limits of excavation/ box cutting the road
surface shall be set out true to lines, curves, slopes, grades and sections as
shown on the drawings or as directed by the Engineer.

3.Box cutting 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 box cutting/ excavation are
satisfactorily utilized as directed.

4.The contractor shall not excavate outside the limits of box cutting. 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 as directed.

5.Cutting shall be done in proper grade & camber as per measurements given.
Care must be taken that all slopes are evenly and truly dressed. Cutting shall
69
be done to the exact depth required and shall be as per formation level in
proper grade and the camber. If extra depth of cutting is done due to
negligence of contractor, the same shall be refilled with approved quality of
materials duly consolidated to the satisfaction of the Engineer-in-charge
(without extra cost).
6.The stuff received from the cutting shall be used for filling and correcting side
slopes of bank as directed by the Engineer in charge.
7.The measurement of box cutting shall be taken on level basis & level shall be
taken at 10 mt. interval. Volume shall be computed in cubic meters by
average area method.
8.The payment shall be made on Cum. basis.
9. The rate includes cost of all labour, machineries required, cost of carting the
cutting stuff with all lead and lift and leveling the dumping ground etc.
complete.

Item No.16: - Providing & laying Earth work including breaking clods
dressing With all lead and lift and including watering, rolling, and
consolidation of subgrade in layers at O.M.C. to required dry density
including filling the depressing which occur during the process using
vibratory roller 8.T. to 10 T.

305 EMBANKMENT CONSTRUCTION

305.1 GENERAL:
305.1.1 Description: These Specifications shall apply to the construction of
embankments including sub grades, earthen shoulders and miscellaneous backfills
with approved materials obtained from contractor’s own earth. No railway land /
Gujarat State land to be used as source of earth, contractor shall arrange own earth.
All embankments, sub grades, earthen shoulders and miscellaneous backfills shall be
constructed in accordance with the requirements of these specifications and in
conformity with the lines, grades, and cross-sections shown on the drawings or as
directed by the Engineer.

305.2 MATERIALS AND GENERAL REQUIREMENTS

305.2.1 Physical requirements:
305.2.1.1The materials used in embankments sub grades, earthen shoulders and
miscellaneous back fills shall be soil, murrum, gravel a mixture of these or any other
material approved by the Engineer. Such materials shall be free of logs, stumps, roots,
rubbish or any other ingredient likely to deteriorate or affect the stability of the
embankment.
The following types of material shall be considered unsuitable for embankment:
(a) Materials from swamps, marshes and bogs;

70
 (b) Peat, log, stump and perishable material and soil that classifies as OL, 01, OH
or Pt in accordance with IS: 1498
(c) Materials susceptible to spontaneous combustion
(d) Materials in a frozen condition
(e) Clay having liquid limit exceeding 70 and plasticity index exceeding 45; and
(f) Materials with salts resulting in leaching in the embankment.
305.2.1.2 Expansive clay exhibiting marked swell and shrinkage, properties ("free
swelling index" exceeding 50 percent when tested as per IS:2720-Part 40) shall not
be used as a fill materia1.Where an expansive clay with acceptable "free swelling
index" value is used as a fill material, sub grade and top 500 mm portion of the
embankment just below sub grade shall be non-expansive in nature.
305.2.1.3 Any fill material with a soluble sulphate content exceeding 1.9 grams of
sulphate (expressed as S03) per liter 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
Cementous materials forming part of the Permanent Works.
Materials with a total sulphate content (expressed as S03) 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 farming
part of the Permanent Work
305.2.1.4 The size of the coarse material in the mixture of earth shall ordinarily not
exceed 75mm when being placed in the embankment and 50 mm when placed in the
sub grade. 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 third of the
compacted layer thickness.

305.2.1.5 Ordinarily, only the materials satisfying the density requirements given
in MORTH Table 300-1 shall be employed for the Construction of the embankment
and the sub grade.

MORTH TABLE 300-1: - DENSITY REQUIREMENTS OF EMBANKMENT AND

SUBGRADE MATERIALS
Maximum Laboratory
dry unit weight when
Sr. No. Type of work
tested as per
IS:2720(part 8)
Embankments up to. 3 meters height, Not less than 15.2
1.
not subjected to extensive flooding. kN/cum.
Embankments exiting 3 meters height of
Not less than 16.0
2. embankments of any height subject to
kN/cum.
long period of inundation

71
 Sub grade and earthen shoulders/ Not less than 17.5
3.
Verges/backfill kN/cu.m.
Notes:
(1) This Table is not applicable for lightweight fill materials 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 materials to be used in sub grade should also. Satisfy design CBR at the dry
unit weight Applicable as per Table 300-2 of MORT&H.
305.2.1.6 The material to be used in subgrade shall conform to the design CBR value
at the specified dry density and moisture content of the test specimen. In case the
available materials fails to meet the requirement of CBR, use of stabilization methods
in accordance with Clauses 403 and 404 or by any stabilization method approved by
the Engineer or by the IRC Accreditation Committee shall be followed.
305.2.1. 7 The material to be used in high embankment construction shall satisfy the
specified requirements of strength parameters.
305.2.2 GENERAL REQUIREMENTS:
305.2.2.1The 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 sub grade and the embankment portion just below the sub grade.
305.2.2.2 Borrow materials: The arrangement for the source of supply of the
material for embankment and sub-grade and compliance with the guidelines, and
environmental requirements, in respect of excavation and borrow areas as stipulated,
from time to time by the Ministry of Environment and Forests, Government of India
and the local bodies, as applicable shall be the sole responsibility of the Contractor.
Borrow pits along the road shall be discouraged. If permitted by the Engineer,
these shall not be dug continuously. Ridges of not less than 8 m width should be left
at intervals not exceeding 300m. Small drains shall be cut through the ridges to
facilitate drainage.The depth of the pits shall be so regulated that their bottom does
not cut an imaginary line having a slope of 1 vertical to 4 horizontal projected from
the edge of the final section of the bank, the maximum depth in any case being limited
to 1.5 m. Also, no pit shall be dug within the offset width from the toe of the
embankment required as per the consideration of stability with a minimum width of
10m.
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.
Where the excavation reveals a combination of acceptable and unacceptable
materials, the Contractor shall, unless otherwise agreed by the Engineer, carry out
the excavation in such a manner that the acceptable materials are excavated
separately for use in the permanent works without contamination by the unacceptable
materials. The acceptable materials shall be stockpiled separately.
The Contractor shall ensure that he does not adversely affect the stability of
excavation or fills by the methods of stockpiling materials, use of plants or sitting of
temporary buildings or structures.
72
305.2.2.4 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 shall be ensured that the sub grade material
when compacted to the density requirements as in MORTH Table 300-2 shall yield the
design CBR value of the sub grade.

MORTH TABLE 300-2:- COMPACTION REQUIREMENTS FOR EMBANKMENT

AND SUB GRADE

Relative compaction as
percentage of
Sr. No. Type of work/material max.1aboratory dry
density as per IS:2720
(part 8)
1 Sub-grade and earthen shoulders Not less than 97%
2 Embankment Not less than 95%
3 Expansive clay
a) Sub grade and 500 mm portion Just below the
Not allowed.
sub-grade
b) Remaining portion of embankment 90-95%

The Contractor shall at least 7 working days before commencement of compaction

submit the following to the Engineer for approval:
(i) The value of maximum dry density and optimum content obtained in accordance
with IS: 2720 (part 8), appropriate for each of the fill materials he intends to use.

(ii) A graph of density plotted against moisture content from which each of the values
in (i) above of maximum dry density and optimum moisture content were
determined.
The maximum dry density and optimum moisture content approved by the Engineer
shall form the basis for compaction.

305.3 CONSTRUCTION OPERATIONS:

305.3.1 Setting Out: After the site has been cleared to Clause 201, the work shall
be set out to Clause 301.3. 1. The limits of embankment/sub grade shall be marked
by fixing batter pegs on both sides at regular intervals as guides before commencing
the earthwork. The embankment/sub grade shall be built sufficiently wider than the
design dimension so that surplus material may be trimmed; ensuring that the
remaining material is to be desired density and the position specified and conforms to
the specified side slopes.
305.3.2 Dewatering: If the foundation of the embankment is in an area with
stagnant water, and in the opinion of the Engineer it is feasible to remove it, the same

73
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, MORTH Clause 305.4.6 shall
apply.
305.3.3 Stripping and Storing topsoil: 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 subjected to traffic either before stripping or when in a stockpile.
Stockpiles shall not be surcharged, or otherwise loaded and multiple handling shall be
kept to a minimum.
305.3.4 Compacting ground supporting embankment Sub grade: 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 MORTH Table 300-2.
In case where the difference between the sub grade level (Top of the sub grade
on which pavement rests) and ground level is less than 0.5 m and the ground does
not have 97 per cent relative compaction with respect to the dry density as given in
MORTH Table 300-2, the ground shall be loosened up to a level 0.5 m below the sub
grade level, watered and compacted in layers in accordance with MORTH Clauses
305.3.5 and 305.3.6 to not less than 97 per cent of dry density as given in Table 300-
2.
Where so directed by the Engineer, any unsuitable material occurring in the
embankment foundation shall be removed and replaced by approved materials laid in
layers to the required degree of compaction.
Embankment or sub grade work shall not proceed until the foundations for
Embankment/sub grade have been inspected by the Engineer for satisfactory
condition and approved.
Any foundation treatment specified for embankments especially high
embankments, resting on suspect foundations as revealed by borehole logs .shall be
carried out in a manner and to the depth as desired by the Engineer. Where the
ground on which an embankment is to be built has any of the ,material types (a) to
(f) in MORTH Clause 305.2.1.1,atleast 500 mm. of such material must be removed
and replaced by acceptable fill material before embankment construction commences.
305.3.5 Spreading material in layers and bringing to appropriate moisture
content
305.3.5.1 The embankment and sub grade material shall be spread in layers of
uniform thickness not exceeding 200mm.compacted thickness over the entire width
of embankment by mechanical means, finished by a motor grader and compacted as
per MORTH 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
74
slope and grade. Successive layers shall not be placed until the layer under
construction has been thoroughly compacted to the specified requirements as in
MORTH Table 300-2 and got approved by the Engineer. Each compacted layer shall
be finished parallel to the final cross-section of the embankment.
305.3.5.2 Moisture content of the material shall be checked at the site of placement
prior to commencement of compaction; if found to be out of agreed limits, the same
shall be made good. Where water is required to be added in such constructions, water
shall be sprinkled from a water tanker fitted with sprinkler capable of applying water
uniformly with a controllable rate of flow to variable widths of surface but without any
flooding. The water shall be added uniformly and thoroughly mixed in soil by balding,
dicing or harrowing until 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 (Part 7) or IS: 2720 (part 8) as the case may be. Expansive
clays shall however, be compacted at moisture content corresponding to the specified
dry density, but on the wet side of the optimum moisture content obtained, from the
laboratory compaction curve.
After adding the required amount of water, the soil shall be processed by means
of graders, harrows, rotary mixers or as otherwise approved by the Engineer until the
layer is uniformly wet.
clods or hard lumps of earth shall be broken to have a maximum size of 75 mm
when being placed in the embankment and a maximum size of 50 mm when being
placed in the sub grade.
305.3.5.3 Embankment and other areas of fill shall, unless otherwise required in the
Contract or permitted by the Engineer, be constructed evenly over their full width and
their fullest possible extent and the Contractor shall control and direct construction
plant and other vehicular traffic uniformly over them. Damage by construction plant
and other vehicular traffic shall be made good by the Contractor with material having
the same characteristics and strength as the material had before it was damaged.
Embankments and other areas of unsupported fills shall not be 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, cutting, other fills and excavations steeper
than 1 vertical on 4 horizontal, such faces shall be benched as per MORTH Clause
305.4.1 immediately before placing the subsequent fill.
All permanent faces of side slopes of embankments and other areas of fill formed
shall, subsequent to any trimming operations, be reworked and sealed to the

75
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.
305.3.6 Compaction: Only the compaction equipment approved by the Engineer
shall be employed to compact the different material types encountered during
construction. Vibratory rollers 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 carrying out compaction trials. The procedure to be adopted for this site trials hall
first be submitted to the Engineer for approval.
Each layer of the material shall be thoroughly compacted to the densities specified
in MORTH Table 300-2. Subsequent layers shall be placed only after the finished layer
has been tested according to MORTH Clause 903.2} 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). The Contractor shall maintain a record of the same.
When density measurements reveal any soft areas in the embankments /sub grade
/earthen shoulders, further compaction shall be carried out as directed by the
Engineer. If in spite of that the specified compaction is not achieved, the material in
the soft areas shall be removed and replaced by approved material, compacted to the
density requirements and satisfaction of the Engineer.
305.3.7 Drainage: The surface of the embankment/ sub grade at all times during
construction shall be maintained at such a cross fall (not flatter than that required for
effective drainage of an earthen surface) as will shed water and prevent ponding.
305.3.8 Repairing of damages caused by rain/spillage of water
The soil in the affected portion shall be removed in such areas as 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 MORTH Clause
305.3.6 If the cut is not sufficiently wide for use of required mechanical means for
compaction, the same shall be widened suitably to permit their use for proper
compaction. Tests shall be carried out as directed by the Engineer to ascertain the
density requirements of the repaired area. The' work of repairing the damages
including widening of the cut, if any, shall be carried out by the Contractor at his own
cost, including the arranging of machinery/equipment for the purpose.
305.3.9 Finishing operations:
Finishing operations shall include the work of shaping and dressing the
shoulders/verge/roadbed and side slopes to conform to the alignment, levels, and
cross sections and dimensions shown on the drawings' or as directed by the Engineer
subject to the surface tolerance described in MORTH Clause 902. Both the upper and
lower ends of the side slopes shall be rounded off to improve appearance and to
merge the embankment with the adjacent terrain.

76
 The topsoil removed and conserved earlier (MORTH Clause 301.3.2 and 305.3.3)
shall be spread over the fill slopes as per directions of the Engineer to facilitate the
growth of vegetation. Slopes shall be roughened and moisture slightly prior to the
application of the topsoil in order to provide satisfactory bond. The depth of the top
soil 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 MORTH
Clause 307. If seeding and mulching of slopes is prescribed, this shall be done to the
requirement of MORTH Clause 308.
When earthwork operations have been substantially completed, the road area shall
be cleared of all debris, and ugly scars in the construction area responsible for
objectionable appearance eliminated.

305.4 Construction of Embankment and sub grade under special

conditions
305.4.1 Earthwork for widening existing road embankment:

When an existing embankment and/or sub grade is to be Widened and its slopes
are steeper than I 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/sub grade material to be added. The material obtained from
cutting of benches could be utilized in the widening of the embankment/sub grade.
However, when the existing slope against which the fresh material is to be placed is
flatter than 1 vertical on 4 horizontal, the slope surface may only be ploughed or
scarified instead of resorting to benching.
Where the width of the widened portions is insufficient to permit the use of
conventional rollers, compaction shall be carried out with the help of small vibratory
rollers/plate compactors/power rammers or any other appropriate equipment
approved by the Engineer. And dumping of material from trucks for widening
operations shall be avoided except in difficult circumstances when the extra width is
too narrow to permit the movement of any other types of hauling equipment.

305.4.2 Earthwork for embankment and sub grade to be placed against

sloping ground:
Where an embankment /sub grade to be place against sloping ground, the latter
shall be appropriately benched or ploughed/scarified as required in MORTH Clause
305.4.1 before placing the embankment /sub grade material. Extra earthwork involved
in benching or due to ploughing /scarifying etc. shall be considered incidental to the
work.
For wet conditions, benches with slightly inward fall and subsoil drains at the
lowest point shall be provided as per the drawings, before the fill is placed against
sloping ground.

77
 Where the contract requires construction of transverse subsurface drain at the cut-
fill interface, work on the same shall be carried out to MORTH Clause 309 in proper
sequence with the embankment and sub grade work as approved by the Engineer.

305.4.3 Earthwork over existing road surface:

Where the embankment is to be placed over an existing road surface, the work
shall be carried out as indicated below,
(i) If the existing road surface is of granular or bituminous type and lies within 1 m
of the new sub grade level, the same shall be scarified to a depth of 50 Rm or
more if specified, o as to provide ample bond between the old and new material
ensuring that at least 500 mm portion below the top of new sub grade level is
compacted to the desired density.
(ii) If the existing road surface is of cement concrete type and lies within 1 m of the
new sub grade level the same shall be removed completely.
(iii) If the level difference between the existing road surface and the new formation level is
more than 1 m, the existing surface shall be roughened after ensuring that the minimum
thickness of 500 mm of subgrade is available.

305.4.4 Embankment and sub grade 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
up to 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 sub grade shall be brought up
simultaneously in equal layers on each side of the structure to avoid displacement and
unequal pressure. The sequence of work in this regard shall be got approved from the
Engineer.
The material used for backfill shall not be all' 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 for Road Bridges-Section VII) in respect
of the Just below the sub grade type of material, the extent of backfill, its laying d
compaction etc. The fill material shall be deposited in horizontal layers in loose
thickness and compacted thoroughly to the requirements of MORTH Table 300-2.
Where the provision of any filter medium is specified behind the abutment, the
same shall be laid in layers simultaneously with the laying of fill material. The material
used for filter shall conform to the requirements for filter medium spelt out in MORTH
Clause 2502/309.3.2 (B) unless otherwise specified in the Contract.

78
 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 ten to see that the compaction equipment
does not hit or come too close to any structural member so as to cause any damage
to them or excessive pressure against the structure.
305.4.5 Construction of embankment over ground incapable of supporting
construction equipment

Where embankment is to 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
geo synthetic 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 MORTH Clause 305.3.
305.4.6 Embankment Construction under Water and Waterlogged Areas
305.4.6.1 Embankment construction under water:
Where filling or backfilling is to be placed under water, only acceptable granular
material or rock shall be used unless otherwise approved by the Engineer. Acceptable
granular material shall consist of graded, hard durable 'particles with maximum
particle size not exceeding 75mm. The material should be non-plastic having
uniformity coefficient of not less than 10. The material placed in open water shall be
deposited' by end tipping without compaction.
305.4.6.2 Embankment Construction in Waterlogged and Marshy Areas
The work shall be done as per IRC:34.
305.4.7Earthwork for high Embankment:
The material for high embankment construction shall conform to Clause 305.2.1. 7.
In the case of high embankments (more than 6 m), the Contractor shall normally use
fly ash in conformity with Clause 305.2.1.1 or the material from the approved borrow
area.
Where provided, stage construction of embankment and 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 the Contractor shall bring the resultant level up to formation
level with acceptable material for use in fill.
79
305.4.8 Settlement period: - Where settlement period is specified in the Contract,
the embankment shall remain in place for the required settlement period before
excavating for abutment, wing wall, 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.
Rolling and watering of earthwork in layers with power roller including
filling in depression which occur during the process.
1. For spreading materials in layers and bringing the appropriate moisture content,
the embankment materials shall be spread uniformly over the entire width of the
embankment in layers not exceeding 250mm in loose thickness, Successive layers
of embankment shall not be placed until the layer under construction has been
thoroughly compacted to the requirements set down here under
Moisture content of the materials shall be checked at the source of supply arid
it found less than that specified for compaction; the same shall be made good
either at the source or after spreading the soil in loose thickness for compaction.
In the latter case, water shall be sprinkled directly from a houseline or from a truck
mounted water tank and flooding shall not be permitted under any circumstances.
If the materials delivered to the road bed is too wet it shall be dried, by
evaporation arid exposure to the sun, till the moisture content is brought done to
acceptable standard for compaction should circumstances arise, where owing to
wet weather, the moisture content cannot be reduced to the required level by the
above procedure. Work of compaction shall be suspended.
Moisture content of each layer of soil shall be checked in accordance with IS
2720 (Part-II) and unless otherwise mentioned shall be so adjusted, making due
allowance for evaporation losses, that at the time of the compaction it is in the
range of 1 percent to 2 percent below the optimum Moisture content determined
in accordance with ISI (Part-VII). Highly expansive clays shall however be
compacted at 2 to 4 percent above the optimum moisture content.
After adding the required amount of water, the soil shall be processed by
means, of harrows. Rotary mixers or as otherwise approved until the layer is
uniformly wet. Clods or hard lumps of earth shall be broken to have maximum size
of 150mm when being placed lower layers of the embankment arid a maximum
size of 60mm when being placed in the top 0.5-meter portion of the embankment
below the sub grade.
Hauling equipment shall be dispersed uniformly over entire surface of the
previously constructed layer to minimize cutting of uneven compaction.
Where the embankment is to be constructed on low area ground that will not
support the weight of trucks of other hauling equipment the lower part of the fill
should be constructed by dumping Successive loads in a uniformly distributed
layers of a thickness not greater than that necessary to support the hauling
equipment while placing subsequent layers.
2. COMPACTION: Only compacting equipment approved by the Engineer-in-charge
shall be employed to compact the materials. The contractor shall demonstrate the
efficiency of the plants he intends to use for carrying out compaction trials.

80
 Each layer of the materials shall be thoroughly compacted to the densities specified
in Table below:
Table:-
Sr. Field dry density/MDD as
No. Type of Work / Materials percentage of maximum laboratory
dry density as per IS : 2720 (Part
VII)
Top 0.5-meter portion of
1 embankment below sub grade level Not less than 97.
and shoulders
2 Other portion of embankment Not less than 95.
3 Highly expensive class 85 to 90.

Subsequent layers shall be placed only after finished layer has been tested
according to M.O.S.T. specification clause 902 and accepted by the Engineer-in-
charge.
When density measurements reveal any soft areas in the embankment further
compaction shall be carried out as directed by the Engineer-in-charge If insight of that
the specified compaction is not achieved, the materials in the soft areas shall be
removed and replaced by approved materials and compacted to the density
requirement, to the satisfaction of the Engineer-in-charge.
3. The contract unit rate includes cost of mechanical roller required for consolidation
including all labour equipment fuel, hire charges, tolls, and incidentals necessary.
305.4.8 Plying of Traffic:
Construction and other vehicular traffic shall not use the prepared surface of the
embankment and/or sub grade without the prior permission of the Engineer. Any
damage arising out of such use shall, however, be made good by the Contractor at
his own expense as directed by the Engineer.
305.6 Surface Finish and Quality Control of Work:
The surface finish of construction of sub grade shall conform to the requirements of
MORTH Clause 902. Control on the quality of materials and works shall be exercised
in accordance with MORTH Clause 903.

305.7 Sub grade Strength:

305.7.1 It shall be ensured prior to actual execution that the borrow area material to
be used in the sub grade satisfies the requirements of design CBR.
305.7.2 Sub grade shall be compacted and finished to the design strength consistent
with other physical requirements. The actual laboratory CBR values of constructed sub
grade shall be determined on undisturbed samples cut out from the compacted sub
grade in CBR mould fitted with cutting shoe or on remoulded samples, compacted to
the field density at the field moisture content.

81
305.8 MEASUREMENTS FOR PAYMENT:
305.8.1 Earth embankment/ sub grade 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 meters by the
method of average end areas.
305.8.2 The measurement of fill material from borrow areas shall be the difference
between the net quantities of compacted fill and the net quantities of suitable material
brought from roadway and drainage excavation. For this purpose, it shall be ass med
that one cum. of suitable material brought to site from road and drainage excavation
forms one cum. of compacted fill and all bulking or shrinkage shall be ignored.
305.8.4 Construction of embankment under water shall be measured in cum.
305.8.5 Construction of high embankment with specified material and in specified
manner shall be measured in cum.
305.8.6 Stripping including storing and reapplication of topsoil shall be measured in
Cum.
305.8.7 Work involving loosening and re-compacting of ground supporting
embankment /sub grade shall be measured in cum.
305.8.8 Removal of unsuitable material at embankment/sub grade foundation and
replacement with suitable material shall be measured in Cum.
305.8.9 Scarifying existing granular /bituminous road surface shall be measured in
Square meters.
305.8.10 Dismantling and removal of existing cement concrete pavement shall be
measured vide MORTH Clause 202.6.
305.8.11 Filter medium and backfill material behind abutments, wing walls and other
retaining structures shall be measured as finished work in position in cum.
305.9 RATES:
305.9.1 The Contract unit rates for the items of embankment and sub grade
construction shall be payment in full for carrying out the required operations including
full compensation for:
(i) Cost of arrangement of land as a source of supply of material of required quantity
for construction, unless provided otherwise in the contract.
(ii) Setting out.
(iii) Compacting ground supporting embankment/sub grade except where removal
and replacement of unsuitable material or loosening and re-compacting is
involved;
(iv) Scarifying or cutting continuous horizontal benches 300mm wide on slopes of
existing embankment and sub grade as applicable;
(v) Cost of watering or drying of material in borrow areas and/or embankment and
sub grade during construction as required.
(vi) Spreading in layers, bringing to appropriate moisture content and compacting to
specification requirements
(vii) Shaping and dressing top and slopes of the embankment and sub grade
including rounding of corners;
(viii) Restricted working at sites of structures

82
(ix) Working on narrow width or embankment and sub grade;
(x) Excavation in all soils from borrow pits/designated borrow areas in jungle
Clearing and grubbing and transporting the material to embankment sub grade
site with all lifts and leads unless otherwise provided for contractor.
(xi) All labour, material, tools, equipment and incidentals necessary to com etc. the
work to the Specifications;
(xii) Dewatering and
(xiii) Keeping the embankment/completed formation free of water as per Clause 311.
In case the Contract unit rate specified is inclusive of all leads, the unit rate for
transporting material beyond the initial lead, as specified in the contract for
construction of embankment and sub grade 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.

Item No.17: - Construction of 150 mm thick compacted coarsed granular

subbase (Grade-I crushed B.T materials of 53 mm to 26.5 mm @ 35 %,26.5
mm to 4.75 mm @ 45% ,Below 2.36 mm @ 20 %) by providing close graded
material , mixing in a mechanical mix plant at OMC,carriage of a mix
material to work site, spreading uniform layers with motor grader on
prepared surface and compacting with vibratory power roller to achieve
desire density , complete clause as per 401.

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

401.2 Materials:
401.2.1 The material to be used for the work shall be natural sand, crushed
gravel, crushed stone, crushed slag, or combination thereof depending upon the
grading required. Use of materials like brick metal, Kankar and crushed concrete shall
be permitted in the lower sub-base. The material shall be free from organic or other
deleterious constituents and shall conform to the gradings given in Table 400-1 and
physical requirements given in Table 400-2. Gradings III and IV shall preferably be
used in lower sub-base. Gradings V and VI shall be used as a sub-base-cum-drainage
layer. The grading to be adopted for a project shall be as specified in the Contract.
Where the sub-base is laid in two layers as upper sub-base and lower sub-base, the
thickness of each layer shall not be less than 150 mm.

401.2.2 If the water absorption of the aggregates determined as per IS:2386 (Part
3) is greater than 2 percent, the aggregates shall be tested for Wet Aggregate Impact
Value (AIV) (IS:5640). Soft aggregates like Kankar, brick ballast and laterite shall also
be tested for Wet AIV (IS:5640).
83
 Table 400-1 : Grading for Granular Sub-base Materials
IS Sieve Percent by Weight Passing the IS Sieve
Designation Grading Grading Grading Grading Grading Grading
I II Ill IV V VI
75.0 mm 100 - - - 100 -
53.0 mm 80-100 100 100 100 80-100 100
26.5 mm 55-90 70-100 55-75 50-80 55-90 75-100
9.50 mm 35-65 50-80 - - 35-65 55-75
4.75 mm 25-55 40-65 10-30 15-35 25-50 30-55
2.36 mm 20-40 30-50 - - 10-20 10-25
0.85 mm - - - - 2-10 -
0.425 mm 10-15 10-15 - - 0.5 0-8
0.075 mm <5 <5 <5 <5 - 0-3

Table 400-2 : Physical Requirements for Materials for Granular Sub-base

Aggregate Impact Value IS:2386 (Part 4) or 40 maximum

(AIV) IS:5640
Liquid Limit IS:2720 (Part 5) Maximum 25
Plasticity Index IS:2720 (Part 5) Maximum 6
CBR at 98% dry density IS:2720 (Part 5) Minimum 30 unless
(at IS:2720-Part 8) otherwise specified in the
Contract

401.3.1 Preparation of Sub-grade

Immediately prior to the laying of sub-base, the subgrade already finished to Clause
301 or
305 as applicable shall be prepared by removing all vegetation and other extraneous
matter,
lightly sprinkled with water, if necessary and rolled with two passes of 80-100 kN
smooth
wheeled roller.

401.3.2 Spreading and Compacting

The sub-base material of the grading specified in the Contract and water shall be
mixed mechanically by a suitable mixer equipped with provision for controlled addition
of water and mechanical mixing. So as to ensure homogenous and uniform mix. The
required water content shall be determined in accordance with IS:2720 (Part 8). The
mix shall be spread on the prepared subgrade with the help of a motor grader of
adequate capacity, its blade having hydraulic controls suitable for initial adjustment

84
and for maintaining the required slope and grade during the operation, or other means
as approved by the Engineer.

Moisture content of the mix shall be checked in accordance with IS:2720 (Part 2) and
suitably adjusted so that, at the time of compaction, it is from 1 to 2 percent below
the optimum moisture content.

Immediately after spreading the mix, rolling shall be done by an approved roller. 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 200
mm the compaction shall be done with the help of a vibratory roller of minimum 80
to 100 kN static weight 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 or on super elevation. For carriageway having
crossfall on both sides, rolling shall commence at the edges and progress towards the
crown.

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

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

401.4 Surface Finish and Quality Control of Work

The surface finish of construction shall conform to the requirements of Clause 902.
Control on the quality of materials and works shall be exercised by the Engineer in
accordance with Section 900.

401.5 Arrangements for Traffic

During the period of construction, arrangements for the traffic shall be provided and
maintained in accordance with Clause 112.

401.6 Measurements 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.
85
401.7 Rate
The Contract unit rate for granular sub-base shall be payment in full for carrying out
the required operations including full compensation for:
i) making arrangements for traffic to Clause 112 except for initial treatment to
verges, shoulders and construction of diversions.
ii) supplying all materials to be incorporated in the work including all royalties,
fees, rents where applicable with 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.

Item No.18: - Construction of granular sub-base 150 mm thick by

providing coasre graded machine crushed B.T. material satisfying
MOST specification of grading II (B.T. stone aggregate 26.5 to 4.75
mm - 75 % and 2.36 mm below - 25 % ) including spreading in
uniform layer with motor grader on prepared surface, mixing by mix
in place method with rotavator at OMC and compacting with vibratory
roller to achieve the desired density etc. complete.

This work shall consist of laying and compacting well graded material on
prepared sub grade in accordance with relevant detailed specification of item
No. 17 of this contract except that the materials to be used for the work shall
be crushed stone free from organic or other deleterious constituents and
confirm to the grading II as mentioned in Table 400

Item No.19: - Providing and laying wet mix base course macadam 250
mm in single layer using machine crushed chips as per required
gradation mixing with required optimum quantity of water conveying
the mix to site and spreading to grade and camber with mechanical
paver consolidation by vibratory roller including material, labour,
plant and machinery and equipment etc. complete.

406.1 SCOPE
This work shall consist of laying and compacting clean, crushed, graded
aggregate and granular material, premixed with water, to a dense mass on a
prepared subgrade sub base/ base or existing pavement as the case may be in
accordance with the requirements of these specifications. The material shall be
laid in one or more layers as necessary to lines, grades and cross-sections
shown on the approved drawings or as directed by the Engineer.
The thickness of a single compacted Wet Mix Macadam layer shall not be less
than 75mm. When vibrating or other approved types of compacting equipment
are used, the compacted depth of a single layer of the sub-base course may be
increased to 20cm upon approval of the Engineer.
86
406.2 MATERIALS
406.2.1 AGGREGATES
406.2.1.1 PHYSICAL REQUIREMENTS :
Course aggregates shall be crushed stone. If crushed gravel / shingle is used,
not less than 90 percent by weight of the gravel / shingle pieces retained on
4.75 mm sieve shall have at least two fractured faces. The aggregates shall
conform to the physical requirements set forth in Table 400-12 below.
If the water absorption value of the coarse aggregate is greater than 2 percent,
the soundness test shall be carried out on the material delivered to site as per
IS:2386 (Part-5).
TABLE 400-12 PHYSICAL REQUIREMENT OF COARSE AGGREGATES
FOR WET MIX MACADAM FOR SUB-BASE / BASE COURSES
Test Test Method Requirements
1.*Los Angeles Abrasion value IS : 2386 (Part-4) 40 percent
(Max)
Aggregate impact value IS : 2386 (Part-4) or 30 percent
IS : 5640 (Max)
2. Combined Flakiness and IS : 2386(PART-1) 35 percent
Elongation indices ( Total )** (Max)

* To determine this combined proportion, the flaky stone from a

representative sample should first be separated out. Flakiness index is weight
of flaky stone metal divided by weight of stone sample only the elongated
particles be separated out from the remaining (non flaky stone metal.
Elongation index is weight of elongated particles divided by total non flaky
particles. The value of flakiness index and elongation index so found are added
up.

406.2.1.2 Grading requirements :

The aggregates shall conform to the grading given in Table 400-13

TABLE 400-13. GRADING REQUIREMENTS OF AGGREGATES FOR

WET MIX MACADAM.
Percent by weight Passing the IS
Is Sieve Designation sieve
53.00 mm 100
45.00 mm 95-100
26.50 mm -
22.40 mm 60-80
11.20 mm 40-60
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 4.75 mm 25-40
2.36 mm 15-30
600.00 micron 8-22
75.00 micron 0-5
Materials finer than 425 micron shall have plasticity index (P.I ) not exceeding
6.

The final gradation approved within these limits shall be well graded from
coarse to fine and shall not very from the low limit on one sieve to the high
limit on the adjacent sieve or vice- versa.
406.3 Construction Operation :
406.3.1 Preparation of base:

The surface of the sub-grade/sub-base/base to receive the water bound

macadam course shall be prepared to the specified grade and camber and
cleaned of dust, dirt and other extraneous material. Any ruts or soft yielding
places shall be corrected in an approved manner
and rolled until firm surface is obtained.

Where the WBM is to be laid on an existing metalled road, damaged area

including depressions and potholes shall be repaired and made good with the
suitable material. The existing surface shall be scarified and re-shaped to the
required grade and camber before spreading the coarse aggregate for WBM.

As far as possible, laying water bound macadam course over existing

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.

406.3.2 Provision of lateral confinement of aggregates :

While constructing wet mix macadam arrangement shall be made for the
lateral confinement of wet mix. This shall be done by laying materials in
adjoining shoulders along with that of wet mix macadam layer and following
the sequence of operations described in Clause 404.3.3 as below.

404.3.3 Lateral Confinement of Aggregates

For construction of WBM, arrangement shall be made for the lateral
confinement of aggregates. This shall be done by building adjoining shoulders
along with WBM layers. The practice of constructing WBM in a trench section
excavated in the finished formation must be completely avoided.

88
Where the WBM course is to be constructed in narrow widths for widening of
an existing pavement, the existing shoulders should be excavated to their full
depth and width up to the sub-grade level except where widening specifications
envisages laying of a stabilized sub-base using in-situ operations in which case
the same should be removed only up to the sub-base level.

406.3.3 Preparation of mix:

Wet Mix Macadam shall be prepared in an approved mixing plant of suitable

capacity having provision for controlled addition of water and forced/ positive
mixing arrangement like pugmill or pan type mixer of concrete batching plant.
The plant shall have following features:
i) For feeding aggregates- three/ four bin feeders with variable speed motor
ii) Vibrating screen for removal of oversize aggregates
iii) Conveyor Belt
iv) Controlled system for addition of water
v) Forced/positive mixing arrangement like pug-mill or pan type mixer
vi) Centralized control panel for sequential operation of various devices and
precise process control
vii) Safety devices
Optimum moisture for mixing shall be determined in accordance with IS:2720
(Part-8) after replacing the aggregate fraction retained on 22.4 mm sieve with
material of 4.75 mm to 22.4 mm size. While adding water, due allowance should
be made for evaporation losses. However, at the time of compaction, water in
the wet mix should not vary from the optimum value by more than agreed
limits. The mixed material should be uniformly wet and no segregation should
be permitted.

406.3.4 Spreading of mix:

Immediately after mixing, the aggregates shall be spread uniformly and evenly
upon the prepared sub-grade/sub-base/base in required quantities. In no case
shall these be dumped in heaps directly on the area where these are to be laid
nor shall their hauling over a partly completed stretch be permitted.
The mix may be spread by a paver finisher. The paver finisher shall be self-
propelled of adequate capacity with following features:
i) Loading hoppers and suitable distribution system, so as to provide a
smooth uninterrupted material flow for different layer thicknesses from
the tipper to the screed.
ii) Hydraulically operated telescopic screed for paving width upto to 8.5
m and fixed screed beyond this. The screed shall have tamping and
vibrating arrangement for initial compaction of the layer.
89
 iii) Automatic levelling control system with electronic sensing device to
maintain mat thickness and cross slope of mat during laying procedure.
In exceptional cases where it is not possible for the paver to be utilized,
mechanical means like motor grader may be used with the prior approval of
the Engineer. The motor grader shall
be capable of spreading the material uniformly all over the surface.
The surface of the aggregate shall be carefully checked with templates and all
high or low spots remedied by removing or adding aggregate as may be
required. The layer may be tested by depth blocks during construction. No
segregation of larger and fine particles should be allowed. The aggregates as
spread should be of uniform gradation with no pockets of fine materials.
The Engineer may permit manual mixing and /or laying of wet mix macadam
where small quantity of wet mix macadam is to be executed. Manual
mixing/laying in inaccessible/ remote locations and in situations where use of
machinery is not feasible can also be permitted. Where manual mixing/laying
is intended to be used, the same shall be done with the approval of the
Engineer.

406.3.5 Compaction
After the mix has been laid to the required thickness, grade and
crossfall/camber the same shall be uniformly compacted to the full depth with
suitable roller. If the thickness of single compacted layer does not exceed 100
mm, a smooth wheel roller of 80 to 100kN weight may be used. For a
compacted single layer upto 200 mm, the compaction shall be done with the
help of vibratory roller of minimum static weight of 80 to 100 kN with an
arrangement for adjusting the frequency and amplitude. An appropriate
frequency and amplitude may be selected. The speed of the roller shall not
exceed 5 km/h.

In portions having unidirectional cross fall/superelevation, rolling shall

commence from the lower edge and progress gradually towards the upper
edge. Thereafter, roller should progress parallel to the center line of the road,
uniformly over-lapping each preceding track by at least one-third width until
the entire surface has been rolled. Alternate trips of the roller shall be
terminated in stops at least 1 m away from any preceding stop.

In portions in camber, rolling should begin at the edge with the roller running
forward and backward until the edges have been firmly compacted. The roller
shall then progress gradually

90
towards the center parallel to the center line of the road uniformly overlapping
each of the preceding track by at least one-third width until the entire surface
has been rolled.

Any displacement occurring as a result of reversing of the direction of a roller

or from any other cause shall be corrected at once as specified and/or removed
and made good.

Along forms, kerbs, walls or other places not accessible to the roller, the mixture
shall be thoroughly compacted with mechanical tampers or a plate compactor.
Skin patching of an area without scarifying the surface to permit proper bonding
of the added material shall not be permitted.

Rolling should not be done when the sub-grade is soft or yielding or when it
causes a wavelike
motion in the sub-base/base course or sub-grade. If irregularities develop
during rolling which exceed 12 mm when tested with a 3m straight edge, the
surface should be loosened and premixed material added or removed as
required before rolling again so as to achieve a uniform surface conforming to
the desired grade and crossfall. In no case shall the use of unmixed material
be permitted to make up the depressions.

Rolling shall be continued till the density achieved is at least 98 percent of the
maximum dry density for the material as determined by the method outlined in
IS:2720 (Part-8).
After completion, the surface of any finished layer shall be well-closed, free
from movement under compaction equipment or any compaction planes,
ridges, cracks and loose material. All loose, segregated or otherwise defective
areas shall be made good to the full thickness of the layer and recompacted.
406.3.6 Setting and Drying
After final compaction of wet mix macadam course, the road shall be allowed
to dry for 24 hours.
406.4 Opening to Traffic
No vehicular traffic shall be allowed on the finished wet mix macadam surface.
Construction equipment may be allowed with the approval of the Engineer.
406.5 Surface Finish and Quality Control of Work
406.5.1 Surface Evenness
The surface finish of construction shall conform to the requirements of Clause
902.
406.5.2 Quality Control

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Control on the quality of materials and works shall be exercised by the Engineer
in accordance
with Section 900.
406.6 Rectification of Surface Irregularity
Where the surface irregularity of the wet mix macadam course exceeds the
permissible tolerances or where the course is otherwise defective due to sub-
grade soil getting mixed with the aggregates, the full thickness of the layer
shall be scarified over the affected area, re-shaped with added premixed
material or removed and replaced with fresh premixed material as applicable
and recompacted in accordance with Clause 406.3. The area treated in the
aforesaid manner shall not be less than 5 m long and 2 m wide. In no case
shall depressions be filled up with unmixed and ungraded material or fines.
406.7 Arrangement for Traffic
During the period of construction, arrangements for traffic shall be done as per
Clause 112.
406.8 Measurements for Payment
Wet mix macadam shall be measured as finished work in position in cubic
metres.
406.9 Rate
The Contract unit rate for wet mix macadam shall be payment in full for carrying
out the required operations including full compensation for all components
listed in Clause 401.7.
The Contract unit rate for Wet mix macadam shall be payment in full for
carrying out the required operations including full compensation for:
i) making arrangements for traffic to Clause 112 except for initial
treatment to verges, shoulders and construction of diversions;
ii) supplying all materials to be incorporated in the work including all
royalties, fees, rents where applicable with all leads and lifts;
iii) all labour, tools, equipment and incidentals to complete the work to
the Specifications;
i) carrying out the work in part widths of road where directed; and
ii) carrying out the required tests for quality control.

Item No.20: - Providing and laying 50 mm DBM in single layer using

crushed stone aggregate BT chips as per required gradation and
using emulsion asphalt as a tack coat @ 2.5 kg / 10 sq.mt. and the
VG-30 grade asphalt at 45 kg/MT)by total weight of mix hot laid
process using hot mix plant including heating and mixing asphalt &
materials by drum mix process transporting the mix and laying by
paver finisher including consolidation with vibratory roller including

92
cost of material, labour, machinery equipment and fuel , oil , lubricant
for plant and machinery using contractor's own plant and machineries
etc. complete

505 DENSE BITUMINOUS MACADAM

505.1 Scope

The specification describes the design and construction procedure for Dense
Bituminous Macadam, (DBM), for use mainly, but not exclusively, in base/binder
and profile corrective courses. The work shall consist of construction in a multiple
layer of DBM on a previously prepared base or sub-base. The thickness of a single
layer shall be 50 mm to 100 mm.

505.2 Materials

505.2.1 Bitumen

The bitumen shall be viscosity grade paving bitumen complying with the Indian
Standard Specification IS:73, modified bitumen complying with Clause 501.2.1 or
as otherwise specified in the Contract.

The type and grade of bitumen to be used shall be specified in the Contract.

505.2.2 Coarse Aggregates

The coarse aggregates shall consist of crushed rock, crushed gravel or other hard
material retained on 2.36 mm sieve. They shall be clean, hard, durable, of cubical
shape, free from dust and soft or friable matter, organic or other deleterious
substances. Where the Contractor's selected source of aggregates has poor
affinity for bitumen, the Contractor shall produce test results that with the use of
anti-stripping agents, the stripping value is improved to satisfy the specification
requirements. The Engineer may approve such a source and as a condition for
the approval of that source, the bitumen shall be treated with an approved anti-
stripping agent, as per the manufacturer's recommendations, at the cost of the
Contractor. The aggregates shall satisfy the requirements specified in Table 500-
8.

Where crushed gravel is proposed for use as aggregate, not less than 90 percent
by weight of the crushed material retained on the 4.75 mm sieve shall have at
least two fractured faces.

505.2.3 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
93
 micron sieve. These shall be clean, hard, durable, dry and free from dust, and
soft or friable matter, organic or other deleterious matter. Natural sand shall not
be allowed in binder courses. However, natural sand upto 50 percent of the fine
aggregate may be allowed in base courses. 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).

505.2.4 Filler

Filter 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.

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. 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 used and percentage of fine aggregate reduced
accordingly.

505.2.5 Aggregate Grading and Binder Content

505.2.5.1 When tested in accordance with IS:2386 Part 1 (wet sieving

method), the combined grading of the coarse and fine aggregates and filler for
the particular mixture shall fall within the limits given in Table 500-10 for grading
1 or 2 as specified in the Contract. To avoid gap grading, the combined aggregate
gradation shall not vary from the lower limit on one sieve to higher limit on the
adjacent sieve.

Table 500-8 : Physical Requirements for Coarse Aggregate for Dense

Bituminous Macadam
Property T e s t Specification Method of Test
Cleanliness (dust) Grain size analysis Max 5% passing IS:2386 Part I
0.075 mm sieve
Particle shape Combined Flakiness Max 35% IS:2386 Part I
and Elongation
Indices*
Strength Los Angeles Max 35% 15:2386 Part IV
Abrasion Value or
Aggregate Impact Value Max 27%

94
Durability Soundness either Max 12% IS:2386 Part V
:Sodium Sulphate or
Magnesium Sulphate Max 18%

Water Absorption Water Absorption Max 2% IS:2386 Part 111

Stripping Coating and Stripping IS:6241
Minimum retained
of Bitumen Aggregate
coating 95%
Mix
Water Sensitivity Min. 80% AASHTO 283
Retained
Tensile
Strength**
* To determine this combined proportion, the flaky stone from a
representative sampleshould first be separated out. Flakiness index is weight of
flaky stone metal divided by weight of stone sample. Only the elongated particles
be separated out from the remaining (non-flaky) stone metal. Elongation index is
weight of elongated particles divided by total non-flaky particles. The values of
flakiness index and elongation index so found are added up.
** If the minimum retained tensile test strength falls below 80 percent, use of
anti stripping agent is recommended to meet the requirement.

Table 500-9 : Grading Requirements for Mineral Filler

Cumulative Percent Passing by Weight of Total
IS sieve (mm)
Aggregate
0.6 100

0.3 95 — 100

0.075 85 — 100

Table 500-10: Composition of Dense Graded Bituminous Macadam

Grading 1 2
Nominal aggregate 37.5 mm 26.5 mm
Layer thicknesssize* 75 — 100 mm 50 — 75 mm
IS Sieve (mm)1 Cumulative % by weight of total aggregate
45 100 passing
37.5 95—100 100
26.5 63—93 90 — 100
19 — 71 — 95

95
 13.2 55—75 56 — 80
9.5 — —
4.75 38—54 38 — 54
2.36 28—42 28 — 42
2.36 1.18 — —
0.6 — —
0.3 7 — 21 7 — 21

0.15 — —
0.075 2—8 2—8
Bitumen content % by mass Min 4.0** Min 4.5**
of total mix

* The nominal maximum particle size is the largest specified sieve size
upon which any of the aggregate is retained.

** Corresponds to specific gravity of aggregates being 2.7. In case

aggregate have specific gravity more than 2.7, the minimum bitumen content
can be reduced proportionately. Further the region where highest daily mean
air temperature is 30°C or lower and lowest daily air temperature is — 10°C or
lower, the bitumen content may be increased by 0.5 percent.
505.2.5.2 Bitumen content indicated in Table 500-10 is the minimum
quantity. The
quantity shall be determined in accordance with Clause 505.3.

505.3 Mix Design

The bitumen content required shall be determined following the Marshall mix
design procedure contained in Asphalt Institute Manual MS-2.

The Fines to Bitumen (F/B) ratio by weight of total mix shall range from 0.6 to
1.2.

505.3.1 Requirements for the Mix

Apart from conformity with the grading and quality requirements for individual
ingredients, the mixture shall meet the requirements set out in Table 500-11.

96
 Table 500-11 : Requirements for Dense Graded Bituminous
Macadam

Properties Viscosity Modified bitumen Test Method

Grade Paving Hot climate Cold climate
Bitumen
Compaction level 75 blows on each face of the specimen
Minimum stability (KN 9.0 12.0 10.0 AASHTO
at 600C) T245

Marshall flow (mm) 2—4 2.5 — 4 3.5 — 5 AASHTO T245

Marshall Quotient 2—5 2.5 — 5 MS-2 and

ASTM D2041
Stability
Flow
% air voids 3—5
% Voids Filled with 65 — 75
Bitumen (VFB)
Coating of aggregate IS:6241
95% minimum
Particle
Tensile Strength ratio 80% Minimum AASHTO T 283
% Voids in Mineral Minimum percent voids in mineral aggregate (VMA)
Aggregate (VMA) are set out in Table 500-13

505.3.2 Binder Content

The binder content shall be optimized to achieve the requirements of the mix
set out in Table 500-11. The binder content shall be selected to obtain 4 percent
air voids in the mix design. The Marshall method for determining the optimum
binder content shall be adopted as described in the Asphalt Institute Manual MS-
2.

Where maximum size of the aggregate is more than 26.5 mm, the modified
Marshall method using 150 mm diameter specimen described in MS-2 and ASTM
D 5581 shall be used. This method requires modified equipment and procedures.
When the modified Marshall test is used, the specified minimum stability values
in Table 500-12 shall be multiplied by 2.25, and the minimum flow shall be 3
mm.

97
Table 500-12 : Minimum Percent Voids In Mineral Aggregate (VMA)

Nominal Maximum Minimum VMA Percent Related to

Particle Size' (mm) Design Percentage Air voids

3.0 4.0 5.0

26.5 11.0 12.0 13.0

37.5 10.0 11.0 12.0

Note : Interpolate minimum voids in the mineral aggregate (VMA)

for designed percentage air voids values between those listed.

505.3.3 Job Mix Formula

The Contractor shall submit to the Engineer for approval at least 21 days before
the start the work, the job mix formula proposed for use in the works, together
with the following details:

i) Source and location of all materials;

ii) Proportions of all materials expressed as follows:

a) Binder type, and percentage by weight of total mix;

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 fraction, and

the proportion of each in the combined grading;

v) The results of mix design such as maximum specific gravity of

loose mix (Gmm), compacted specimen densities, Marshall
stability, flow, air voids, VMA, VFB and related graphs and test
results of AASHTO T 283 Moisture susceptibility test;

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.

98
While establishing the job mix formula, the Contractor shall ensure that it is
based on a correct and truly re presentative sample of the materials that will
actually be used in the work and that the mix and its different ingredients satisfy
the physical and strength requirements of these Specifications.

The mix job formula shall be based on the mix design prepared by GERI or Govt.
Approved laboratory & same shall be got approved from Executive Engineer.

Approval of the job mix formula shall be based on independent testing by the
Engineer for which samples of all ingredients of the mix shall be furnished by
the Contractor as required by the Engineer.

The approved job mix formula shall remain effective unless and until a revised
Job Mix Formula is approved. Should a change in the source of materials be
proposed, a new job mix formula shall be forwarded by the Contractor to the
Engineer for approval before the placing of the material.

505.3.4 Plant Trials — Permissible Variation in Job Mix Formula

Once the laboratory job mix formula is approved, the Contractor shall carry out
plant trials to establish that the plant can produce a uniform mix conforming to
the approved job mix formula. The permissible variations of the individual
percentages of the various ingredients in the actual mix from the job mix formula
to be used shall be within the limits as specified in Table 500-13 and shall remain
within the gradation band. These variations are intended to apply to individual
specimens taken for quality control tests in accordance with Section 900.

Table 500-13 : Permissible Variations in the Actual Mix from the

Job Mix Formula

Description Base/binder Course

Aggregate passing 19 mm sieve or larger ± 8%
Aggregate passing 13.2 mm, 9.5 mm ± 7%
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%
Mixing temperature ± 10°C

99
505.3.5 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 and compacted all in accordance with Clause 501. The
laying trial shall be carried out on a suitable area which is not to form part of
the works. 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 is capable of
producing satisfactory results. The density of the finished paving layer shall be
determined by taking cores, no sooner than 24 hours after laying, or by other
approved method. The compacted layers of Dense Graded Bituminous Macadam
(DBM) shall have a minimum field density equal to or more than 92% of the
density based on theoretical maximum specific gravity (0mm) obtained on the
day of compaction in accordance with ASTM D 2041.

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.

505.4 Construction Operations

505.4.1 Weather and Seasonal Limitations

The provisions of Clause 501.5.1 shall apply.

505.4.2 Preparation of Base

The base on which Dense Graded Bituminous Material is to be laid shall be

prepared in accordance with Clauses 501 and 902 as appropriate, or as directed
by the Engineer.
505.4.3 Geosynthetics

Where Geosynthetics are specified in the Contract, this shall be in accordance

with the requirements stated in Clause 703.

505.4.4 Stress Absorbing Layer

Where a stress absorbing layer is specified in the Contract, this shall be applied
in accordance with the requirements of Clause 517.

100
505.4.5 Prime Coat

Where the material on which the dense bituminous macadam is to be laid is

other than a bitumen bound layer, a prime coat shall be applied, as specified, in
accordance with the provisions of Clause 502, or as directed by the Engineer.

505.4.6 Tack Coat

Where the material on which the dense bituminous macadam is to be laid is

either bitumen bound layer or primed granular layer, tack coat shall be applied,
as specified, in accordance with the provisions of Clause 503, or as directed by
the Engineer.

505.4.7 Mixing and Transportation of the Mix

The provisions as specified in Clauses 501.3 and 501.4 shall apply. Table 500-2
gives the mixing, laying and rolling temperature for dense mixes using viscosity
grade bitumen. In case of modified bitumen, the temperature of mixing and
compaction shall be higher than the mix with viscosity grade bitumen. The exact
temperature depends upon the type and amount of modifier used and shall be
adopted as per the recommendations of the manufacturer. In order to have
uniform quality, the plant shall be calibrated from time to time.

505.4.8 Spreading
The provisions of Clauses 501.5.3 and 501.5.4 shall apply.

505.4.9 Rolling

The general provisions of Clauses 501.6 and 501.7 shall apply, as modified by
the approved laying trials. The compaction process shall be carried out by the
same plant, and using the same method, as approved in the laying trials, which
may be varied only with the express approval of the Engineer in writing.

505.5 Opening to Traffic

It shall be ensured that the traffic is not allowed without the approval of the
Engineer in writing, on the surface until the dense bituminous layer has cooled
to the ambient temperature.

505.6 Surface Finish and Quality Control of Work

The surface finish of the completed construction shall conform to the
requirements of Clause 902. All materials and workmanship shall comply with
the provisions set out in Section 900 of these Specifications.

101
505.7 Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in
accordance with the provisions of Clause 112.

505.8 Measurement for Payment

Dense Graded Bituminous Materials shall be measured as finished work in
Tonnes of specified thickness as indicated in the Contract drawings, or
documents, or as otherwise directed by the Engineer.
505.9 Rate
The contract unit rate for Dense Graded Bituminous Macadam shall be payment
in full for carrying out all the required operations as specified and shall include,
to all components listed in Clause 501.8.8.2. The rate shall include the provision
of bitumen, at 4 percent and 4.5 percent by weight of the total mixture for
grading 1 and grading 2 respectively.
No Extra payment shall be made for extra consumption of bitumen which is due
to variation in proportion of bitumen in mix design & specified in the description
of item above.

Item No.21:- Providing and laying 50 mm thick compacted B.M.with

B.T. aggregate as per MORT&H specification and Emulsion grade RS1
for tack coat at 2.5 Kg./10Sq.mt. with mechanical sprayer and
bitumen grade 60/70 (VG-30) for mixing at the rate 34.0Kg/M.T. i.e.
3.4 % of total mix including heating the aggregate and asphalt by
drum mix plant and spreading the same by censor paver finisher and
consolidation with vibratory roller including providing all materials,
equipments, tools and plants, oil, kerosene, fire wood, labour charges
etc. complete.
Scope :-
This work shall consist of bituminous construction in a single course
having 50 mm thickness course of compacted crushed aggregates premixed
with a bituminous binder on a previously prepared base to the requirements of
these specification. Since the bituminous macadam is an open graded mix,
there is a potential that it may trap water or moisture vapour within the
pavement system. Therefor, adjacent layer should have proper drainage quality
to prevent moisture-induced damage to BM.

504.2 Materials :-
504.2.1 Bitumen :-
The bitumen shall be viscosity grade paving bitumen complying with
Indian standard specification for paving bitumen, IS:73 or as specified in
102
contract. The type and grade of bitumen to be used would depend upon the
climatic conditions and the traffic. Guidelines for selection of bitumen are given
in Table 500-1.
504.2.2 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 substences. 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.
504.2.3 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 75 micron
sieve. They shall be clean hard, durable, dry and free from dust, and soft or
friable matter, organic or other deleterious substances. Natural sand shall not
be used in the binder course.

Table 500.6 Physical, Requirements of Coarse

aggregates
Property Test Specification Test Method
Cleanliness Grain Size analysis Max. 5% passing IS : 2386 Part I
0.075 mm sieve.
Particle shape Flakiness and Max. 35% IS : 2386 Part I
Elongation Index
(Combined)
Strength Los Angeles Max. 40% IS : 2386 Part
Abrasion Value or IV
Aggregate Impact Max. 30% IS : 2386 Part
Value IV
Durability Soundness (Sodium
or Magnesium) 5 Cycles

Sodium Sulphate Max. 12% IS : 2386 Part V

Magnesium Max. 18% IS : 2386 Part V
Sulphate
Water Water Absorption Max. 2% IS : 2386 Part III
Absorption

103
 Property Test Specification Test Method
Stripping Coating and Minimum IS : 6241
stripping of Bitumen retained coating
aggregate Mixtures. 95%
Water Retained Tensile Minimum 80% AASHTO 283
Sensitivity Strength*

*If the minimum retained tensile strength falls below 80 %, use of anti
stripping agent is recommended to meet the minimum requirements.
504.2.4 Aggregate grading and binder content :-
The combined grading of the coarse aggregate and fine aggregate, when
tested in accordance with IS:2386 Part-I, wet sieving method, shall conform to
limits given in Table 500-8. The type and quantity of bitumen and appropriate
thickness is also given in Table 500-7.
504.2.5 Proportioning of material :-
The combined aggregate grading shall not vary from the lower limit on
one sieve to the higher limit on the adjacent sieve to avoid gap grading. The
aggregate may be proportioned and blended to produce a uniform mix
complying with the requirements of Table 500-7. The binder content shall be
within a tolerance of + 0.3 % by weight of total mix when individual specimens
are taken for quality control tests in accordance with the provisions of Section
900.
504.3 Construction Operations :-
504.3.1 Weather and seasonal limitations :-
The provisions of Clause 501.5.1 shall apply.
Table 500.7 Aggregate Grading and Bitumen Content
Grading Grading-2
Nominal Maximum 19 mm
aggregate size *
layer thickness 50 mm
IS : Sieve [MM] Cumulative % by weight of total
aggregate passing.
26.5 100
19 90 – 100
13.2 56 – 88
4.75 16 – 36
2.36 4 – 19
0 .3 2 – 10
0.075 0–8

104
 Bitumen content ** % 3.40
by weight of total
mixture
Bitumen Grade (VG-30)
* Nominal maximum aggregate size is the largest specified sieve size
upon which any of the material is retained.
** Corresponds to specific gravity of the aggregate being 2.7.In case
aggregate have specific gravity more than 2.7, bitumen content can be
reduced proportionately. Further for regions where highest daily mean
air temperature is 30°c or lower and lowest daily mean air temperature
-10°c or lower, the bitumen content may be increased by 0.5 percent.
504.3.2 Preparation of the base :-
The base on which bituminous macadam is to be laid shall be prepared
shaped and compacted to the required profile in accordance with Clauses-501.8
and 902.3 as appropriate and a prime coat, shall be applied in accordance with
Clause-502 where specified or as directed by the Engineer. The surface shall
be thoroughly swept clean by mechanical broom and the dust removed by
compressed air. In location where mechanical broom cannot get access, other
approved methods shall be used as directed by the Engineer.

504.3.3 Tack coat :-

A tack coat in accordance with Clause-503 shall be applied as required
by the contract documents or as directed by the Engineer.
504.3.4 Preparation and transportation of the mixture:-
The provisions of Clauses 501.3 & 501.4 shall apply.
504.3.5 Spreading :-
The provisions of Clause 501.5.3 shall apply.
504.3.6 Rolling :-
Compaction shall be carried out in accordance with the provisions of Clauses
501.6 and 501.7 as below.
Rolling shall be continued until the specified density is achieved or where no
density is specified until there is no further movement under the roller. The
required frequency of testing is defined in Clause 903.
504.4 Surface finish and Quality control of work :-
The surface finish of the completed construction shall conform to the
requirements of Clause-902 as under. For control of the quality of materials
and the works carried out, the relevant provisions of section 900 shall apply.
504.5 Protection of the Layer :-
The bituminous macadam shall be covered with either the next pavement
course of wearing course as the case may be within a maximum of 48 Hours.
105
If there is to any delay the course shall be covered by MSS before opening to
any traffic. The MSS in such cases shall be considered incidental to the work
and shall not be paid for separately.

504.6 Arrangements for traffic :-

During the period of construction, arrangements for traffic shall be made
in accordance with the provisions of Clause 112 .
504.7 Measurement for Payment :-
Bituminous macadam shall be measured as finished work in Metric Tonne
as indicated in the contract or shown in drawing, or as otherwise directed by
the Engineer.

504.8 Rate :- The contract unit rate for bituminous macadam shall be
payment in full for carrying out the required operations as specified. The rate
shall include for all components listed below.
(i) Making arrangements for traffic to clause 112 except for initial
treatment to verge, shoulders and construction of diversions.
(ii) Preparation of the surface to revive the materials.
(iii) Providing all materials to be incorporated in the work including
arrangement for stock yards. All royalties, fees rents where
necessary and all leads and lifts.
(iv) 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 specification.
(vi) Carrying out the work in part widths of the road where directed.
(vii) Carrying out all tests for control of quality, and
(viii) The rate shall cover the provision of bitumen at the rate specified
in the contract, with the provision that the variation in actual
percentage of bitumen used will be assessed and the payment
adjusted accordingly.
(ix) The rate for premixed material are to include for all wastage in
cutting of joints etc.
(x) The rates are to include for all necessary testing mix design
transporting and testing of samples, and cores. If there is not a
project specific : laboratory, the contractor must arrange to carry
out all necessary testing at an outside laboratory approved by
the Engineer, and all costs incurred are deemed to be included
in the rate quoted for the material.

106
 (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 materials.

Item No.22:- Providing and Laying 25 mm thick Semi Dense

Bituminous Carpet with B.T. aggregate as per M.O.R.T. & H. gradation
and specification with on B.T. Surface of grade ( VG-30 ) for mixing
@ 50.00 Kg/M.T. i.e. 5.0% by weight of total mix including heating
& mixing the aggregate and asphalt by continuous batching of drum
mix plant and spreading the same by paver finisher and consolidation
with power roller, including providing all materials equipments, tools
and plants, oil, kerosene, firewood, labour charges etc. complete
using contractor's own machineries drum mix plant and paver finisher
etc. complete.
This work shall consist of construction in a single layer of semi dense bituminous
concrete on a previously prepared bituminous bound surface. A single layer
shall be 25mm in thickness.
508.2 Materials :-
508.2.1 Binder :-
The binder shall be a viscocity grade of VG-30grade as specified in the
contract satisfying the requirement of IS : 73
508.2.2 Coarse aggregates :-
The coarse aggregates shall consist of crushed rock retained on the 2.36
mm sieve. They shall be clean, hard, durable of cubical shape, free from dust
and set of 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 aggregate shall
be tested for stripping.
The aggregates shall satisfy the physical requirements set forth in Table
500-16 as under.
Table 500.16 Physical, Requirements for Coarse aggregates
Property Test Specification
Max. 5% passing 0.075
Cleanliness Grain Size analysis
mm sieve.
Flakiness and Elongation
Particle shape Max. 30%
Index (Combined)
Los Angeles Abrasion
Strength Max. 40%
Value
107
 Property Test Specification
Aggregate Impact Value Max. 30%
Soundness
Durability
Sodium Sulphate Max. 12%
Magnesium Sulphate Max. 18%
Water Absorption Water Absorption Max. 1%
Coating and stripping of
Minimum retained
Stripping Bitumen aggregate
coating 95%
Mixtures.
Minimum 80%
Water Sensitivity Retained Tensile Strength

Notes :-
[1] IS : 2386 Part – 1 [2] IS : 2386 Part – 1 [the elongation test to be done
only on non-flaky aggregate in the sample] [3] IS : 2386 Part – 4 [4] IS : 2386
Part – 5 [5] IS : 2386 Part – 3 [6] IS : 6241 [7] The water sensitivity test is
only to be carried out if the minimum retained coating in the stripping test is
less than 95 %
* Aggregate may satisfy requirements of either of these two tests.

508.2.3 Fine aggregates :-

The Fine aggregates shall consist of crushed rock, passing the 2.36 mm
sieve and retained on the 75 micron sieve. These shall be clean, hard, durable,
uncoated mineral particles, dry and free from injurious, soft or flaky particles
and organic or deleterious matter.
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)
508.2.4 Filler :- Filler shall consist of finely divided mineral matter such as
rock dust, hydrated lime or cement approved by the Engineer.
The filler shall be graded within the limits indicated in Table 500-9
TABLE 500-9. GRADING REQUIREMENTS FOR MINERAL FILLER
IS Sieve Cumulative percent passing by weight of total
(mm) 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
108
when the limestone aggregate is used. Where the aggregate 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.

508.2.5 Aggregate grading and binder content :-

When tested in accordance with IS :2386 Par I (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 grading II as specified in the
contract.

Table 500.15 Composition of Semi Dense Bituminous Concrete

Pavement Layers
Grading 2
Nominal 10 mm
aggregate size
layer thickness 25 mm

IS : Sieve [MM] Cumulative % by weight of total

aggregate passing.
13.2 100
9.5 90 – 100
4.75 35 - 51
2.36 24 - 39
1.18 15 - 30
0.6 -
0.3 9 - 19
0.15 -
0.075 3-8
Bitumen content % 5.00
by weight of total
mixture
Bitumen Grade VG-30
Note: 1 The combined aggregate grading shall not vary from the below
limit on one sieve to the high limit on adjacent sieve.
2 Determined by the marshal method
The quantity of binder used for premixing in terms of straight run
bitumen 60/70 grade shall be 5.0% by weight of total mix.

109
508.3. Mixture Design
508.3.1 Requirements for the mixture:
Apart from conformity with the grading and quality requirements for individual
ingredients the mixture shall meet the requirements set out in Table 500 -16

Table 500-16. Requirements for Semi Dense Bituminous Pavement Layers

Minimum stability (kn at 600C 8.2
Minimum flow (mm) 2
Maximum flow (mm) 4
Compaction level (Number of blows) 75 blows on each of the
two faces of the specimen
Per cent air voids 3.5
Per cent voids in mineral aggregate (VMA) See table 500-12
Per cent voids filled with bitumen (VFB) 65 - 78

Table 500-12. Minimum per cent voids in mineral aggregate (VMA)

Nominal Maximum Minimum VMA, per cent related to Design Air
particle Size (mm) Voids, Per cent
3.0 4.0 5.0
9.5 14.0 15.0 16.0
12.5 13.0 14.0 15.0
19.0 12.0 13.0 14.0
25.0 11.0 12.0 13.0
37.5 10.0 11.0 12.0

Notes : 1 The nominal maximum particle size is one size larger than the first
sieve to retain more than 10 per cent.
2. Interpolate minimum voids in the mineral aggregate (VMA) for
design air voids value between those listed.
508.3.2 Binder Content
The binder content shall be optimized 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 26.5mm sieve and retained on the 22.4mm
sieve, where approved by the Engineer.
508.3.3 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;
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(i) Source and location of all materials;
(ii) Proportion of all materials expressed as follows where each is applicable;
(a) Binder type, and percentage by weight of total mixture;
(b) Coarse aggregate/ Fine aggregate/ Mineral filler as percentage by
weight of total aggregate including mineral filler;
(iii) A single definite percentage passing each sieve for the mixed aggregate;
(iv) The individual gradings of the individual aggregate fractions and the
proportion of each in the combined grading.
(v) The results of tests enumerated in Table 500-16 as obtained by the
contractor.
(vi) Where the mixture is a batch mixer, the individual weight 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 supply
of materials be proposed, a new job mix formula shall be forwarded to the
Engineer for approval before the placing of the material.
508.3.4 Plant trials - permissible variation in job mix formula:
Once the laboratory job mix formula is approved, the Contractor shall
carry out trials at the mixer to establish that the plant can be set up to produce
a uniform mix conforming to the approved job mix formula. The permissible
variations of the individual percentage of the various ingredients in the actual
mix from the job mix formula to be used shall be within the limits as specified
in Table 500-13. These variations are intended to apply to individual specimens
taken for quality control tests in accordance with section 900.
Table 500-13. Permissible Variations from the Job Mix Formula
Description Permissible variation
Base/binder Wearing
course course
Aggregate passing 19mm sieve or larger +8% +7%
Aggregate passing 13.2mm, 9.5mm +7% +6%
111
 Description Permissible variation
Base/binder Wearing
course course
Aggregate passing 4.75 +6% +5%
Aggregate passing 2.36mm, 1.18mm, +5% +4%
0.6mm
Aggregate passing 0.3mm, 0.15mm +4% +3%
Aggregate passing 0.075mm +2% + 1.5 %
Binder content + 0.3 % + 0.3 %
Mixing temperature + 100C + 100C
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.
508.3.5 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 and compacted all in accordance with Clause 501.
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 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 is
capable of producing satisfactory results. The density of the finished paving
layer shall be determined by taking cores, no sooner than 24 hours after laying,
or by other approved method.
Once the laying trials have been approved, the same plant and
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.
508.4 Construction Operations :-
The provision of following Clauses shall apply.
508.4.1 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
112
bituminous surface, prime or tack coat, shall be blow 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 to be laid is below 10 0 C
or when the wind speed at any temperature exceeds 40 K.M./H at 2 Mt. height
unless specifically approved by the Engineer.

508.4.2 Preparation of base :-

The surface on which the bituminous concrete is to be laid shall be
prepared in accordance with Clause 501 and 902 as appropriate, or as directed
by the Engineer. The surface shall be thoroughly swept clean by mechanical
broom and dust removed by compressed air. In location where a mechanical
broom can not access, other approved methods shall be used as directed by
the Engineer.
508.4.6 Mixing and transportation of the mixture. :-
The provisions as specified in Clause 501.3 and 501.4 shall apply
501.3 Mixing : Pre-mixed bituminous materials including semi dense
bituminous concrete, shall be prepared in a drum mix plant of adequate
capacity and capable of yielding a mix of proper and uniform quality with
thoroughly coated aggregates. Appropriate mixing temperatures shall be as per
Table 500-5
Table 500.5 Manufacturing and Rolling Temperatures.
Penetration Bitumen Aggregate Mixed Rolling Laving
Mixing Mixing Material [C] [C] [C]
[C] [C]
35 106-170 160-175 170 Maximum 100 130
Maximum Maximum
65 150-165 150-170 165 Maximum 90 125
Maximum Maximum
90 140-160 140-165 155 Maximum 80 115
Maximum Maximum
The difference in temperature between the binder and aggregate should
at no time exceed 140C. In order to ensure uniform quality of the mix and better
coating of aggregate, the hot mix plant shall be calibrated from time to time.
501.4 : Transporting
Bituminous material 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.
113
508.4.7 Spreading : -
The premixed material shall be spread by suitable means to the desired
thickness grades and cross-fall. Except in areas where a mechanical paver
cannot access, bituminous materials shall be spread, leveled 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 paver, and its method of
operation, 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.
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 lying binder course or wearing course approaching an
expansion joint of a structure, machine laying shall stop 300mm short of the
joint. The remainder of the pavement up to the joint, 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 the Engineer.
Hand placing of pre-mixed bituminous materials shall only be permitted in the
following circumstances:
1. For laying regulating courses of irregular shape and varying
thickness.
2. In confined spaces where it is impracticable for a paver to
operate.
3. For footways,
4. At the approaches to expansion joint at bridges, viaduct or
other structures,
5. For filling of pot holes
6. 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
114
(ii) At the approaches to expansion joints at bridges, viaducts or
other structures.
(iii) As directed by the Engineer.
508.4.8 Rolling :
As soon as sufficient length of bituminous material has been laid, rolling shall
commence with 8-10 tonne rollers smooth wheel tandem type or other
approved equipment. Rolling shall begin at the edge and progress toward the
center longitudinally except that on supper elevated and unidirectional
cambered portions it shall progress from the lower to upper edge parallel to
the center 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
proceeding track shall be overlapped uniformly by at least 1/3 width. The roller
wheels shall be kept damp to prevent the premix from adhering to the wheels.
In no case shall fuel, lubricating oil be used for this purpose. Excess use of
water for this purpose shall also be avoided.
Rollers shall not stand on newly laid material. Rolling operations shall be
completed in every respect before the temperature of the mix falls below the
minimum rolling temperature stated in the relevant part of these
Specifications.. Joints along and transverse to the surfacing 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 coat of appropriate binder before the new
mix is placed against it.
508.5. 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.
508.6. Surface Finish and Quality Control
The surface finish of the completed construction shall conform to the
requirements of Clause 902 of MORT & H Specification. All materials and
workmanship shall comply with the provisions set out in Section 900 of MORT
& H Specification.
508.7. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in
accordance with the provisions of Clause 112 of MORT&H Specifications.
508.8 Measurement for Payment :-
The payment shall be made on the tonnage basis of the weight of mix
aggregates and bitumen. For this purpose, the contractor shall have to install
a weigh-bridge of suitable capacity for the purpose of weighing dumpers at
115
suitable place at his cost as directed. Weight of empty dumpers and weight of
loaded dumper will be recorded in bound and numbered register on plant site.
Department will be free to get some loaded dumpers test checked at
other weigh bridge. Weigh bridge will be periodically got calibrated and verified
from weight and measure authorities.
For the purpose of application of tack coat, if the theoretical area as per
sanctioned estimate for basis of tonne differs with the actual area of work done
in the field then the reduction in or addition to payment shall have to be
effected to the contractor on pro-rate basis depending upon the area reduced
or exceeded respectively.
Weight of mix materials will be done in presence of responsible person,
not less than the rank of Supervisor of Department and the measurements shall
be recorded by the Deputy Executive Engineer or Assistant Engineer or
Additional Assistant Engineer, if so authorized. Record of each dumper will be
mentioned separately in bond and numbered register which will be maintained
by the Department representatives and signed by the contractor. Proper gate
pass system shall be established for the vehicle coming to the plant site and
going from the site. The location of the K.M. hectometer and meter in which
individual dumpers are unloaded shall be recorded carefully.
508.9 Rate for premixed bituminous materials : - The contract unit rate
shall include the provision of bitumen at 5 % by weight of total mixture. The
variance in actual percentage of bitumen used will be assessed and the
payment adjusted for down only. The unit rate for premixed bituminous
material shall be payment in full for carrying out the required operation
including full compensation for, but not limited to:
1. Making arrangements for traffic to clause 112 except for initial
treatment to verge, shoulders and construction of diversions.
2. Preparation of the surface to revive the materials.
3. Providing all materials to be incorporated in the work including
arrangement for stock yards. All royalties, fees rents where necessary and all
leads and lifts.
4. Mixing transporting, laying and compacting the mix as
specified.
5. All labour, tools equipment, plant including installation of hot
mix plant, power supply units and all machinery incidental to complete the work
to these specification.
6. Carrying out the work in part widths of the road where
directed.
7. Carrying out all tests for control of quality, and

116
8. 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.
9. The rate for premixed material are to include for all wastage
in cutting of joints etc.
10. 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.
11. 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
materials.

Item No.23: - Providing and applying priming coat with emulsion SS1
grade at the rate of 7.5 kg/ 10 Sq.mt. including cost of asphalt and
preparing the surface heating and applying etc. complete.

502.1 Scope
This work shall consist of the application of a single coat of low viscosity liquid
bituminous material to a porous granular surface preparatory to the
superimposition of bituminous treatment or mix. The work shall be carried out
on a previously prepared granular/ stabilized surface to Clause 501.8.
502.2 Materials
502.2.1 The primer shall be cationic bitumen emulsion SS1 grade conforming
to IS:8887 or medium curing cutback bitumen conforming to IS:217 or as
specified in the Contract.

502.2.2 Quantity of SS 1 grade bitumen emulsion for various types of

granular surface shall be as given in Table 500-3.

TABLE 500-3. Quantity of Bitumen Emulsion for Various Types of

Granular Surfaces
Type of Surface Rate of Spray (kg/sq.m)
WMM/WBM 0.7-1.0

117
 Stabilized soil bases/Crusher 0.9-1.2
Run Macadam

502.2.3 Cutback for primer shall not be prepared at the site. Type and quantity
of cutback bitumen for various types of granular surface shall be as given in
Table 500-4.
TABLE 500-4. Type and Quantity of Cutback Bitumen for Various
Types of Granular Surface
Type of Surface Type of Cutback Rate of Spray
(kg/sq.m)
WMM/WBM MC 30 0.6-0.9
Stabilized soil MC 70 0.9-1.2
bases/Crusher Run
Macadam

502.2.4 The correct quantity of primer shall be decided by the Engineer and
shall be such that it can be absorbed by the surface without causing run-off of
excessive primer and to achieve desired penetration of about 8-10 mm.

502.3 Weather and Seasonal Limitations

Primer shall not be applied during a dust storm or when the weather is foggy,
rainy or windy or when the temperature in the shade is less than 1 DOC.
Cutback bitumen as primer shall not
be applied to a wet surface. Surfaces which are to receive emulsion primer
should be damp, but no free or standing water shall be present. Surface can
be just wet by very light sprinkling of water.
502.4 Construction
502.4.1 Equipment
The primer shall be applied by a self-propelled or towed bitumen pressure
sprayer equipped for spraying the material uniformly at specified rates and
temperatures. Hand spraying shall not be allowed except in small areas,

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inaccessible to the distributor, or in narrow strips where primer shall be sprayed
with a pressure hand sprayer, or as directed by the Engineer.

502.4.2 Preparation of Road Surface

The granular surface to be primed shall be swept clean by power brooms or
mechanical sweepers and made free from dust. All loose material and other
foreign material shall be removed completely. If soil/ murrum binder has been
used in the WBM surface, part of this should be brushed and removed to a
depth of about 2 mm so as to achieve good penetration.
502.4.3 Application of Bituminous Primer
After preparation of the road surface as per Clause 502.4.2, the primer shall be
sprayed uniformly at the specified rate. 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.
No heating or dilution of SS1 bitumen emulsion and shall be permitted at site.
Temperature of cutback bitumen shall be high enough to permit the primer to
be sprayed effectively though the jets of the spray and to cover the surface
uniformly.

502.4.4 Curing of Primer and Opening to Traffic

A primed surface shall be allowed to cure for at least 24 hours or such other
higher period as is found to be necessary to allow all the moisture/volatiles to
evaporate before any subsequent surface treatment or mix is laid. Any
unabsorbed primer shall first be blotted with a light application of sand, using
the minimum quantity possible. A primed surface shall not be opened to traffic
other than that necessary to lay the next course.
502.5 Quality Control of Work
For control of the quality of materials and the works carried out, the relevant
provisions of Section 900 shall apply.
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502.6 Arrangements for Traffic
During construction operations, arrangements for traffic shall be made in
accordance with the provisions of Clause 112.
502.7 Measurement for Payment
Prime coat shall be measured in terms of surface area of application in square
metres.

502.8 Rate
The contract unit rate for prime coat shall be payment in full for carrying out
the required operations including full compensation for all components listed in
Clause 401.7 (i) to (v) 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 quantity at 0.6 kg per square metre or at the rate
specified in the Contract, with adjustment, plus or minus, for the variation
between this quantity and the actual quantity approved by the Engineer after
the preliminary trials referred to in Clause 502.4.3.

Item No.24:- Providing and laying Compacted of Specified quarry Spall in

side shoulder including carraige of material and spreading on prepared
base including compacting as per MOST Specification etc. complete.

1. The quarry spall shall be of approved quality as approved by the Executive

Engineer prior to collection.
2. The quarry spall shall comply the grading requirement as stated below.
GRADING FOR QUARRY SPALL
Sieve Designation Per cent passing by IS sieve
75.0 mm 100
53.0 mm 80-100
26.5 mm 55-90
9.50 mm 35-65
4.75 mm 25-55
2.36 mm 20-40
0.425 mm 10-25
0.075 mm 3-10
CBR Value (Minimum) 20
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 The quarry spall shall be hard, tough, solid durable of black trap quarry of
close texture free from decay and weathering. The stone shall be angular
and roughly cubical in shape and round elongated or flaky materials shall
be rejected. No unsound or long rubble or angular chips smaller than
specified size shall be allowed.
3. All unsound weathered or disintegrated stone obtained from the under
surface layer of the quarry or other layers of boulders shall be rejected.
4. Wherever any doubt as to whether above requirement are satisfied in
whole or part of the collecting it shall be got screened by the contractor if
so ordered by the Executive Engineer and for which no extra payment shall
be claimed by the contractor.
5. Any collection which does not fully satisfy the above requirements is liable
to be rejected all together.
6. Stacking shall be made by the contractor for quantity of required layer.
7. Stacks shall as per actual requirement and any materials in excess shall be
have to be transported by the contractor at the places directed by the
Engineer in charge at the risk and cost of the contractor.
8. If desired and directed by the Engineer-in-charge the contractor shall have
to stack stone aggregates in standard measure boxes of steel of size 2.0
mt. x 1.50 mt. x 0.50 mt. on road side for which no extra payment will be
made to the contractor.
9. The permission for spreading the quarry spall shall be given by the
Engineer in charge if
(i) The full quantity of a particular kilometer is completely collected.
(ii) The levels are recorded in the field book.
10. Q.S. shall if required, be screened, if containing rubbish dust, grass etc. it
shall than be filled in basket & conveyed where required and spread evenly
on the prepared surface be given twisting motion to the basket at the time
of spreading. The surface shall then (15 m) be leveled by means of
templates and strings as well as with camber boards and spirit level
11. Between the straight length and curves and at the meeting points of the
convex and concave portions of the reverse curves, the change in camber
of the road, due to super elevations shall be made as well as with camber
boards and spirit level.
12. At the time of spreading Q.S. a small quantity (about 4 to 5 percent) of
metal as directed shall be retained at the first instance. It shall be spread
later on after partial consolidation as required to rectify the camber and to
fill up the hollows if any. No extra amount shall be paid for this.

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13. The surface shall be brought to the required camber which shall be
checked at every 50 ft. (15 M.) by means off templates while the length
of the in between shall be tested by strings and corrected as required.
14. Pegs shall be driven on either side of the road and joined with strings true
and parallel with a distance between them equal to the width be laid with
quarry spall Similarly.
15. The Q.S. shall be laid as close as possible so as to leave minimum possible
interstices and voids.
16. Before rolling is allowed on quarry spall, the side berms shall be filled upto
the top of the soling and at least 3'-0" (1 m.) on either side so as to prevent
quarry spall layer getting disturbed at times during rolling.
17. Immediately following the spreading of the Quarry Spall, rolling shall be
started with vibratory roller. The capacity of the vibrating roller shall
depend upon the type of the aggregate and shall be indicated by Engineer-
in-charge.
18. Except on super elevated portions where the rolling shall proceed from
inner edge to 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
inwards parallel to center line of the road in successive passes uniformly
lapping preceding tracks by at least one half the width.
19. Rolling shall continue until the aggregate is thoroughly keyed and the
creeping of the aggregate ahead of the roller is no longer visible. During
rolling slight sprinkling of water may be done, if necessary. Rolling shall
not be done when the sub-grade is soft or yielding or when it causes wave
like motion in the sub-grade or sub-base course.
20. The rolled surface shall be checked transversely and longitudinal with
templates and any irregularities corrected by loosening the surface, adding
or removing necessary amounts of aggregate and rerolling until, the entire
surface conforms to desired camber and grade. In no case shall the use of
screening be permitted to make up depression.
21. The blindage material where it is required to be used 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 moving roller

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22. After the final compaction the road shall be allowed to dry overnight. Next
morning hungry spots shall be filled with screenings of binding materials
as directed, lightly sprinkled with water if necessary and rolled. No traffic
shall be allowed on the road until the surface has set. The Engineer-in-
charge shall have the discretion to stop hauling traffic from using the
completed surface if in his opinion it would cause excessive damage to the
surface.
23. Payment will be made on Cum basis of the finished work and Rate shall
include cost of quarry spall, spreading, rolling & watering, rent of
machinery cost fuel, wages of drivers and cleaners and royalty etc.
Measurement shall be taken by cross sectional area method and level shall
be taken at 30 mt. C/C interval.

Item No.25: - Providing and applying asphalt painting on B.T. surface

with mechanical sprayer using bitumen 60/70 (VG-30) at the rate of
5.00 Kg/10 Sq.mt. & spreading stone dust on painting surface at the
rate of 0.03 Cu.m./10 Sq.mt. and rolling with smooth wheeled and
pneumatic roller and brushing etc. complete.
1 Scope :-
This work shall consist of the application of a single coat of bitumen VG-
30 grade to an existing bituminous road surface in accordance with the
following specifications.
2 Materials :-
2.1 Bitumen :-The bitumen used for asphalt painting shall be 60/70 (VG-30)
grade complying with IS: 73 or as directed by the Engineer.
2.2 Stone Dust :-
2.2.1. This shall be obtained from crushing hard black trap or equivalent. It
shall not contain more than 8% of silt as determined by field test will measuring
cylinder. The method of determining silt contents by fields test is given as under.
2.2.2. A sample of stone dust to be tested shall be placed without drying in
200 mm. measuring cylinder. The quantity of the sample shall be such that it
fills the cylinder up to 100 mm. mark. The clean water shall be added up to 150
mm. mark. The mixture shall be stirred vigorously and the content allowed to
settle for 3 hours.
2.2.3. The height of silt, visible as settled layer above the stone dust shall be
expressed as percentage of the height of the stone dust below The stone dust
containing more than 8% silt shall be washed so as to bring the content within
the allowable limit.
2.2.4. The fineness modules of stone dust shall not be less than 1.80

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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 then 100 C.
4 Construction :-
4.1 Equipment :-
The asphalt painting shall be applied through a distributor and it 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 in narrow strips, shall be sprayed with a pressure hand sprayer
or as directed by the Engineer.
4.2 Preparation of base :-
The surface on which the asphalt painting is to be applied shall be clean
and free from dust, dirt and any extraneous material and other wise prepared
in accordance with the requirements of Clauses-501.8 & 513 of MORT & H as
appropriate. Immediately before the application of the asphalt painting the
surface shall be swept clean with a mechanical broom and high-pressure air jet
or by other means as directed by the Engineer.
4.3 Application of asphalt painting :- The application of asphalt for
painting shall be at 5.0 Kg/ 10 Sq.mt. as specified in the contract and shall be
applied uniformly. The asphalt shall be heated in the tanker and the
temperature of the asphalt at the time of spraying shall be in the range of 1500C
-1770C.
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 a spraying trial that the
equipment and method to be used is capable of producing a uniform spray,
within the tolerances specified.
5.0 Spreading of Stone Dust
Soon after the spraying of asphalt, the stone dust shall be spread evenly
with a twisting motion of baskets at the rate of 0.03Cum/10 Sqm. The entire
surface shall be broomed to ensure uniform application of the stone dust. While
the traffic is allowed on the painted surface and at later stage if additional
stone dust is required, it shall be carried out by the contractor without any extra
payment.
6.0 Rolling
As soon as sufficient length of asphalt painting work along with flushing
of stone dust has been completed, rolling shall commence with a pneumatic
tyred roller. Rolling shall begin at the edge and progress towards the center
longitudinally except that on super elevated and unidirectional cambered
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portions, it shall progress from the lower to upper edge parallel to the center
line of the pavement.
In each pass of the roller, the preceding track shall be overlapped
uniformly by at lest 1/3 width. Rolling shall be continued till the whole surface
is compacted satisfactorily.
7.0 Opening to Traffic :-
Traffic may be allowed immediately after completion of rolling.

8.0 Arrangement of Traffic :-

The provision of MOST Specification Clause 112 shall apply as regards the flow
of traffic during construction.
9.0 Mode of Measurement & Payment :
The Item shall be measured and paid as finished work in Square meters. The
rates shall include the cost of all materials, labour, equipments etc. involved in
all the operations described above. The rate shall be for a unit of one sq. meter .

Item No.26: - Providing and applying tack coat with emulsion RS1 grade at
the rate of 3.0 kg/ 10 Sq.mt. including cost of asphalt and preparing the
surface heating, and applying etc. complete.

503.1 Scope

The work shall consist of the application of a single coat of low viscosity liquid
bituminous material to existing bituminous, cement concrete or primed granular
surface preparatory to the superimposition of a bituminous mix, when specified in the
Contract or as instructed by the Engineer. The work shall be carried out on a previously
prepared surface in accordance with Clause 501.8.

503.2 Materials

The binder used for tack coat shall be either Cationic bitumen emulsion (RS 1)
complying with 15:8887 or suitable low viscosity paving bitumen of VG 10 grade
conforming to 15:73. The use of cutback bitumen RC:70 as per 15:217 shall be
restricted only for sites at sub-zero temperatures or for emergency applications as
directed by the Engineer. The type and grade of binder for tack coat shall be as
specified in the Contract or as directed by the Engineer.

503.3 Weather and Seasonal Limitations

Bituminous material shall not be applied during a dust storm or when the weather is
foggy, rainy or windy or when the temperature in the shade is less than 1 ooc. Where

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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.

503.4 Construction

503.4.1 Equipment

The tack coat shall be applied by a self-propelled or towed bitumen pressure sprayer,
equipped for spraying the material uniformly at a specified rate. Hand spraying shall
not be permitted except in small areas, inaccessible to the distributor, or narrow strips,
shall be sprayed with a pressure hand sprayer, or as directed by the Engineer.

503.4.2 Preparation of Base

The surface on which the tack coat is to be applied shall be clean and free from dust,
dirt, and
any extraneous material, and be otherwise prepared in accordance with the
requirements of Clauses 501.8. The granular or stabilized surfaces shall be primed as
per Clause 502. Immediately before the application of the tack coat, the surface shall
be swept clean with a mechanical broom, and high pressure air jet, or by other means
as directed by the Engineer.

503.4.3 Application of Tack Coat

The application of tack coat shall be at the rate specified in Table 500-5, and it shall
be applied uniformly. If rate of application of Tack Coat is not specified in the contract,
then it shall be the rate specified in Table 500-5. No dilution or heating at site of RS1
bitumen emulsion shall be permitted. Paving bitumen if used for tack coat shall be
heated to appropriate temperature in bitumen boilers to achieve viscosity less than 2
poise. The normal range of spraying temperature for a bituminous emulsion shall be
20°C to 70°C and for cutback, 50°C to 80°C. The method of application of tack coat
will depend on the type of equipment to be used, size of nozzles, pressure at the spray
bar, and speed or 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.

Table 500-5 : Rate of Application of Tack Coat

Type of Surface Rate of Spray of Binder in

Kg per sq. m
Bituminous surfaces 0.20-0.30
Granular surfaces treated with primer 0.25-0.30
Cement concrete pavement 0.30-0.35

503.4.4 Curing of Tack Coat

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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.

503.5 Quality Control of Work

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

503.6 Arrangements for Traffic

During the period of construction, arrangements for traffic shall be made in

accordance with the provisions of Clause 112.

503.7 Measurement for Payment

Tack coat shall be measured in terms of surface area of application in square metres.

503.8 Rate

The contract unit rate for tack coat shall be payment in full for carrying out the required
operations including for all components listed in Clause 401.8 (i) to (v) 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 or at the rate specified in the
Contract, with the provision that the variation between this quantity and actual quantity
of bitumen used will be assessed and the payment adjusted accordingly.

Item No.27: - Road marking with hot applied thermo plastic paints
with reflectorizing glass beads on bitumen surface providing and
laying a hot applied thermoplastic compound 2.5 mm thick including
reflecting glass beads@ 250 gms per sqm area, thickness of 2.5mm is
excluding of surface applied glass beds as per IRC-35 2015. The
finished surface to be level, uniform and free from streaks and holes.
zebra patta/bump patta lane/center line/edge line/cut patta. The
white color marking should provide luminance coefficient on cement
road shall be min 130mcd/m2/lux and Asphalt road shall be min 100
mcd/m2/lux during the service life during the day time. The marking
should meet the performance criteria for night time reflectivity, wet
reflectivity and skid resistance as mentioned in the section 15 of
IRC35-2015. warranty for retro reflectivity shall be two years.

803 ROAD MARKINGS

803.1 Scope

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The work shall consist of providing road markings of specified width, layout and
design using paint of the required specifications as given in the Contract and as
per guidelines contained in from IRC:35-1997.

803.2 Materials

Road markings shall be of ordinary road marking paint hot applied thermoplastic
compound, reflectorized paint or cold applied reflective paint as specified in the
item and the material shall meet the requirements as specified in these
Specifications.

803.3 Ordinary Road Marking Paint

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

803.3.2 The road marking shall preferably be laid with appropriate road
marking machinery.

803.4 Hot Applied Thermoplastic Road Marking

803.4.1 Thermoplastic Material

803.4.1.1 General

The thermoplastic material shall be homogeneously composed of aggregate,

pigment, resins and glass reflectorizing beads. The colour of the compound shall
be white or yellow (IS colour No. 356) as specified in the drawings or as directed
by the Engineer.

803.4.1.2 Requirements :

i) Composition: The pigment, beads, and aggregate

shall be uniformly dispersed in the resin. The
material shall be free from all skins, dirt and
foreign objects and shall comply with requirements
indicated in Table 800-9.

Table 800-9 : Proportions of Constituents of Marking Material

(Percentage by Weight)
Component White Yellow
Binder 18.0 min. 18.0 min.
Glass Beads - 30-30 30-30
Titanium Dioxide 10.0 min. —
Calcium Carbonate and Inert Fillers 42.0 max. See Note below
Yellow Pigments -- See Note below
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Note : Amount of yellow pigment, calcium carbonate and inert fillers shall
be at the option of the manufacturer, provided all other
requirements of this Specification are met.

ii) Properties: The properties of thermoplastic material, when

tested in accordance with ASTM D36/BS-3262-(Part
I), shall be as below:

a) Luminance :
White: Daylight luminance at 45°-65 percent min.
as per AASHTO M 249
Yellow: Daylight luminance at 45°-45 percent min.
as per AASHTO M 249
b) Drying time : When applied at a temperature
specified by the manufacturer and to the required
thickness, the material shall set to bear traffic in not
more than 15 minutes.
c) Skid resistance: not less than 45 as per
BS:6044.
d) Cracking resistance at low temperature: The
material shall show no cracks on application to
concrete blocks.
e) Softening point: 102.5°C ± 9.5°C as per ASTM
D 36.
f) Yellowness index (for white thermoplastic paint):
not more than 0.12 as per AASHTO M 249

iii) Storage life : The material shall meet the

requirements of these Specifications for a period of
one year. The thermoplastic material must also melt
uniformly with no evidence of skins or unmelted
particles for the one year storage period. Any
material not meeting the above requirements shall
be replaced by the manufacturer/supplier/
Contractor.
iv) Reflectorisation : Shall be achieved by incorporation of
beads, the grading and other properties of the
beads shall be as specified in Clause 803.4.2.

129
 v) Marking : Each container of the thermoplastic material
shall be clearly and indelibly marked with the
following information:
1) The name, trade mark or other means of
identification of manufacturer
2) Batch number
3) Date of manufacture
4) Colour (white or yellow)
5) Maximum application temperature and maximum
safe heating temperature.
vi) Sampling and Testing : The thermoplastic material shall
be sampled and tested in accordance with the
appropriate ASTM/BS method. The Contractor shall
furnish to the Engineer a copy of certified test
reports from the manufacturers of the
thermoplastic material showing results of all tests
specified herein and shall certify that the material
meets all requirements of this Specification.
803.4.2 Reflectorizing Glass Beads
803.4.2.1 General
This Specification covers two types of glass beads to be used for the production
of reflectorized pavement markings.
Type 1 beads are those which are a constituent of the basic thermoplastic
compound vide Table 800-9 and Type 2 beads are those which are to be
sprayed on the surface vide Clause 803.6.4.

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

These shall conform to the requirements spelt out in Clause 803.4.2.3.

803.4.2.3 Specific Requirements

a) Gradation : The glass beads shall meet the gradation
requirements for the two types as given in Table 800-10.

Table 800-10 : Gradation Requirements for Glass Beads

Sieve Size Percent Retained

Type '1 Type 2
1.18 mm 0 to 3

130
 850 micron 5 to 20 0 to 5
600 micron 5 to 20
425 micron 65 to 95 - -
_ 30 to 75
300 micron --
180 micron 0-10 10 to 30
Below 180 micron -- 0 to 15

b) Roundness: The glass beads shall have a minimum of 70

percent true spheres.

c) Refractive index: The glass beads shall have a minimum

refractive index of 1.50.

d) Free flowing properties: The glass beads shall be free

of hard lumps and clusters and shall dispense readily
under any conditions suitable for paint striping. They shall
pass the free flow-test.

803.4.2.4 Test Methods

The specific requirements shall be tested with the following methods:

i) Free-flow test: Spread 100 grams of beads evenly in a 100 mm diameter

glass dish. Place the dish in a 250 mm inside diameter dessicator which is
filled within 25 mm of the top of a dessicator plate with sulphuric acid water
solution (specific gravity 1.10). Cover the dessicator and let it stand for 4
hours at 20°C to 29°C. Remove sample from dessicator, transfer beads to a
pan and inspect for lumps or clusters. Then pour beads into a clean, dry glass
funnel having a 100 mm stem and 6 mm orifice. If necessary, initiate flow by
lightly tapping the funnel. The glass spheres shall be free of lumps and
clusters and shall flow freely through the funnel.

ii) The requirements of gradation, roundness and refractive index of glass

beads and the amount of glass beads in the compound shall be tested as per
BS:6088 and BS:3262 (Part I).

iii) The Contractor shall furnish to the Engineer a copy of certified test reports
from the manufacturer of glass beads obtained from a reputed laboratory
showing results of all tests specified herein and shall certify that the material
meets all requirements of these Specifications. However, if so required, these
tests may be carried out as directed by the Engineer.

803.4.3 Application Properties of Thermoplastic Material

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803.4.3.1 The thermoplastic material shall readily get
screeded/extruded at temperatures specified by the manufacturers for
respective method of application to produce a line of specified thickness which
shall be continuous and uniform in shape having clear and sharp edges.

803.4.3.2 The material upon heating to application temperatures shall not

exude fumes, which are toxic, obnoxious or injurious to persons or property.

803.4.4 Preparation

i) The material shall be melted in accordance with the

manufacturer's instructions in a heater with a mechanical
stirrer to give a smooth consistency to the thermoplastic
material to avoid local overheating. The temperature of the
mass shall be within the range specified by the manufacturer,
and shall on no account be allowed to exceed the maximum
temperature stated by the manufacturer. The molten material
should be used as expeditiously as possible and for
thermoplastic material which has natural binders or is otherwise
sensitive to prolonged heating, the material shall not be
maintained in a molten condition for more than 4 hours.
ii) After transfer to the laying equipment, the material shall be
maintained within the temperature range specified by the
manufacturer for achieving the desired consistency for laying.

803.5 Reflectorized Paint

Reflectorized paint, if used, shall conform to the Specification by the

manufacturers and approved by the Engineer. Reflectorizing glass beads for
reflectorizing paints where used shall conform to the requirements of Clause
803.4.2.

803.6 Application

803.6.1 Marking shall be done by machine. For locations where painting

cannot
be done by machine, approved manual methods shall be used with prior
approval of the Engineer. The Contractor shall maintain control over traffic
while painting operations are in progress so as to cause minimum
inconvenience to traffic compatible with protecting the workmen.

803.6.2 Where the compound is to be applied to cement concrete pavement, a

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

803.6.3 The thermoplastic material shall be applied hot either by screeding or

extrusion
process. After transfer to the laying apparatus, the material shall be laid at
a temperature within the range specified by the manufacturer for the particular
method of laying being used. The paint shall be applied using a screed or
extrusion machine.

803.6.4 The pavement temperature shall not be less than 10°C during
application. All
surfaces to be marked shall be thoroughly cleaned of all dust, dirt, grease,
oil and all other foreign matter before application of the paint.

The material, when formed into traffic stripes, must be readily renewable by
placing an overlay of new material directly over an old line. Such new material
shall so bond itself to the old line that no splitting or separation takes place.

Thermoplastic paint shall be applied in intermittent or continuous lines of

uniform thickness of at least 2.5 mm unless specified otherwise. Where arrows
or letters are to be provided, thermoplastic compound may be hand-
sprayed. In addition to the beads included in the material, a further
quantity of glass beads of Type 2, conforming to the above noted
Specification shall be sprayed uniformly into a mono-layer on to the hot paint
line in quick succession of the paint spraying operation. The glass beads shall
be applied at the rate of 250 grams per square metre area.

803.6.5 The minimum thickness specified is exclusive of surface applied glass

beads.
The method of thickness measurement shall be in accordance with
Appendices B and C of BS:3262 (Part 3).

803.6.6 The markings shall be done to accuracy within the tolerances given
below:

i) Width of lines and other markings shall not deviate

from the specified width by more than 5 percent.
ii) The position of lines, letters, figures, arrows and other
markings shall not deviate from the position specified
by more than 20 mm
iii) The alignment of any edge of a longitudinal line shall
not deviate from the specified alignment by more than
10 mm in 15 m.

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 iv) The length of segment of broken longitudinal lines
shall not deviate from the specified length by more
than 150 mm.

In broken lines, the length of segment and the gap between segments shall
be as indicated on the drawings; if these lengths are altered by the Engineer,
the ratio of the lengths of the painted sections shall remain the same.

803.6.7 Properties of Finished Road Markings

The finished lines shall be free from ruggedness on sides and ends and be
parallel to the general alignment of the carriageway. The upper surface of
the lines shall be level, uniform and free from streaks.

a) The stripe shall not be slippery when wet.

b) The marking shall not lift from the pavement in
freezing weather.
c) After application and proper drying, the stripe shall show
no appreciable
deformation or discoloration under traffic and under
road temperatures upto 60°C.
d) The marking shall not deteriorate by contact with
sodium chloride, calcium chloride or oil dripping from
traffic.
e) The stripe or marking shall maintain its original
dimensions and position. Cold ductility of the material
shall be such as to permit normal movement with the
road surface without chopping or cracking.
f) The colour of yellow marking shall conform to IS
Colour No. 356 as given in IS:164

Special Requirement for Hot Applied Thermoplastic Marking and

Audible Vibratory Profile Marking Application on Road
1. The application of Hot Applied Thermoplastic and Audible Vibratory marking
must be done with Either Fully Automatic or Semi-Automatic Application
Machine only. No Manual Machine is allowed to use for the application of the
Thermoplastic marking.

2. The Applicator must have their own machines for Thermoplastic profile
Marking, and the proof ownership to be submitted to the Authority for source
approval.

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3. The Applicator should be either Manufacturer or authorized by the original
manufacturer of the Material. The applicator should submit such authorization
certificate to the Authority for the approval before commencing the work.
4. The manufacture should be ISO certified organization and the copy of the
certificate should be submitted to the Authority.

5. Performance Criteria: Material should be confirming to MoRTH specification

and test Certificate should be submitted as per the IRC 35-2015 for the
reflectivity and luminance test time to time.

6. The Applicator should organize onsite testing for the reflectivity performance
with reflectometer initially at 7 days and afterwards at interval of every 6
months up to 2Years. And performance should meet IRC 35-2015 criteria.

7. The Applicator should submit in original warranty for satisfactory in field

performance as laid down in IRC 35-2015 for the period of 2 years. The
warranty should be in original and jointly signed by the original manufacture
and Authorized applicator.

803.6.8 Measurements for Payment

803.6.8.1The painted markings shall be measured in sq. meters of actual

area marked
(excluding the gaps, if any).

803.6.8.2 In respect of markings like directional arrows and lettering,

etc., the measurement shall be by numbers.

803.6.9 Rate

The Contract unit rate for road markings shall be payment in full compensation
for furnishing all labour, materials, tools, equipment, including all incidental
costs necessary for carrying out the work at the site conforming to these
Specifications complete as per the approved drawing(s) or as directed by the
Engineer and all other incidental costs necessary to complete the work to these
Specifications.

Item No.28: - Cat Eye / Road Stud / RPM: Supplying of Molded Twin
Shanks Raised Pavement Markers made of polycarbonate and ABS
molded body and reflective panels with micro prismatic lens capable
of providing total internal reflection of the light entering the lens face
and shall support a load of 13635 kgs. tested in accordance to ASTM

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D 4280 Type H and complying to Specifications of Category A of
MORTH Circular No RW/NH/33023/10-97 DO III Dt 11.06. 1997. The
height, width and length shall not exceed 20 mm, 130 mm and 130
mm and with minimum reflective area of 13 Sq.cm. on each side and
the slope to the base shall be 35 +/- 5 degree. The strength of
detachment of the integrated cylindrical shanks, (of diameter not less
than 19 +/- 2 mm and height not less than 30+/- 2 mm) from the
body is to be a minimum value of 500 Kg. Fixing will be by drilling
holes on the road for the shanks to go inside, without nails and using
epoxy resin based adhesive as per manufacturers recommendation
and the color of the marker should be as per the IRC 35-2015 and as
directed by Engineer-in-charge.

Special Requirements for the Cat Eye/ Road Stud I RPM Application
1. The applicator of the Cat Eye should be authorized Applicator/ Converter of
the original manufacturer of the Cat Eye I road studs and copy of the certificate
has to be submitted to authority for source approval.

2. For Cat eye with twin molded Shanks application the anchorage should be
provided by drilling with the Drilling machine only and not manually.

3. The applicator use the epoxy adhesive or fixing of the Cat eye I RPM as
recommended by the original manufacturer only. No other adhesive should be
allowed to use on the road.

4. Performance Criteria: Material should be confirming to MoRTH specification

and Test Certificate should be submitted as per the IRC 35-2015 for the
reflectivity and luminance test time to time. The Applicator should submit a
letter in original issued by the original manufacturer of the RPM I Cat Eye for
the same before commencing the work.

5. The applicator should submit warranty for satisfactory in field performance

as laid down in IRC 35-2015 for the period of 2 years. The warranty should be
in original and jointly signed by the original manufacture and Authorized
applicator.

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 1.0 Measurement for Payment
The measurement of Cats eye shall be in NUMBERS of markers
supplied and fixed.
2.0 Rate
The contact unit rate for Cats eye shall be payment in full compensation for
furnishing all labour, material, tools, equipment including incidental costs
necessary for carrying out the work at site conforming to the specifications
complete as per approved drawings or as directed.

Item No.29: - Cautionary Warning Sign :-Providing and fixing sign

boards made out of 2mm aluminium sheet / 4mm ACP (Aluminum
composite Panel); size 90 x 90 x 90 cms. equilateral triangle as per
design of IRC-67-2012. Pre treated with phospheting process & acid
etching; coated with one coat of epoxy primer and two coats of best
quality epoxy paint ;reflectorised with Micro Prismatic Grade retro
refiectivesheeting of Type-11 as per ASTM D-4956 and latest
M.O.S.T.Specifications; 3.6mtr long stand post of 75 x 75 x 6mm /
65NB Circular MS Pipe as required and frame fabricated from suitable
size iron angle of 35 x 35 x 3mm; painted with bestquality epoxy
coatings in black and white bends. The details of symbol foreach
board shall be as per theinstruction of engineer in charge. The fixing
at site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each
leg.including excavation, curing etc.complete under the supervision
of engineer in charge. A warranty for 10 years for the Retro reflective
sheeting from original manufacturer & a certified copy of 3 year
outdoor exposure test report from third party test lab for the product
offered shall be submitted by contractor. (A) Class-C Type-11 Retro
Reflective sheeting.

801.1. General
The work shall consist of the fabrication, supply and installation of ground
mounted traffic signs on roads. The details of the signs shall be as shown in
the drawings and in conformity with the Code of Practice for Road Signs,
IRC:67-2010.

801.2. Materials
The various materials and fabrication of the traffic signs shall conform to the
following requirements:
801.2.1. Concrete : Concrete for foundation shall be of M 15 Grade as per
Section 1700 or the grade shown on the drawings or otherwise as directed by
the Engineer.

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801.2.2. Reinforcing steel: Reinforcing steel shall conform to the
requirement of IS:1786 unless otherwise shown on the drawing.
801.2.3. Bolts, nuts, washers: High strength bolts shall conform to IS : 1367
whereas precision bolts, nuts, etc., shall conform to IS: 1364.
801.2.4. Plates and supports: Plates and support sections for the sign posts
shall conform to IS: 226 and IS: 2062 or any other relevant IS Specifications.
801.2.5 Substrate
Sign panels shall be fabricated on aluminium sheet, aluminium composite panel,
fibre glass sheeting, or sheet moulding compound. Aluminum sheets used for
sign boards shall be of smooth, hard and corrosion resistant aluminium alloy
conforming to IS:736-Material Designation 24345 or 1900.Aiuminium
Composite Material (ACM) sheets shall be sandwiched construction with a
thermoplastic core of Low Density Polyethylene (LOPE) between two thick
skins/sheets of aluminium with overall thickness and 3 mm or 4 mm (as
specified in the Contract), and aluminium skin of thickness 0.5 mm and 0.3 mm
respectively on both sides.
The mechanical proportion of ACM and that of aluminium skin shall conform to
the requirements given in Table 800-1, when tested in accordance with the test
methods mentioned against each of them.

Table 800-1 : Specifications for Aluminium Composite Material

(ACM)
Sr. No. Description Specification
Standard Test Acceptable Value
A Mechanical Properties of ACM
1) Peel off strength ASTM 0903 Min. 4 N/mm
with retro reflective
2) Tensile strength ASTM E8 Min. 40 N/mm2
3) 0.2% Proof Stress ASTM E8 Min. 34 N/mm2
4) Elongation ASTM E8 Min.6%
5) Flexural strength ASTM 393 Min. 130 N/mm2
6) Flexural modulus ASTM 393 Min. 44.00 N/mm2
7) Shear strength with ASTM 732 Min. 30 N/mm2
Punch shear test
B Properties of Aluminium Skin
1) Tensile strength ASTM E8 Min. 65 N/mm2
(Rm)
2) Modulus of elasticity ASTM E8 Min. 70,000 N/mm2

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 3) Elongation ASTM E8 A50 Min. 2%
4) 0.2% Proof Stress ASTM E8 Min. 10 N/mm2

801.2.6 Plate Thickness

Shoulder mounted ground sings with a maximum side dimension not exceeding
600 mm shall not be less than 1.5 mm thick with Aluminium and 3 mm thick
with Aluminium Composite Material. All other signs be at least 2 mm thick with
Aluminium and 4 mm thick with Aluminium Composite Material. The thickness
of the sheet shall be related to the size of the sign and its support and shall be
such that it does not bend or deform under prevailing wind and other loads.
801.2.7 In respect of sign sizes not covered by IRC:67, the structural details
(thickness, etc.) shall be as per the approved drawings or as directed by the
Engineer.
801.3 Traffic Signs having Retro-Reflective Sheeting
801.3.1 General Requirements
The retro-reflective sheeting used on the sign shall consist of the white or
coloured sheeting having a smooth outer surface which has the property of
retro-reflection over its entire surface.
It shall be weather-resistant and show colour fastness. It shall be new and
unused and shall show no evidence of cracking, scaling, pitting, blistering, edge
lifting or curling and shall have negligible shrinkage or expansion. A certificate
of having tested the sheeting for co-efficient of retro-reflection, day/night time
colour luminous, shrinkage, flexibility, linear removal, adhesion, impact
resistance, specular gloss and fungus resistance and its having- passed these
tests shall be obtained from a Government Laboratory/Institute, by the
manufacturer of the sheeting. The retro-reflective sheeting shall be either of
Engineering Grade material with enclosed lens, High Intensity Grade with
encapsulated lens or Micro-prismatic Grade retro-reflective element material as
given in Clauses 801.3.2 to 801.3. 7. Guidance on the recommended application
of each class of sheeting may be taken from IRC:67.

801.3.2 High Intensity Grade Sheeting

801.3.2.1 High Intensity Grade (Type Ill)
This high intensity retro reflective sheeting shall be of encapsulated lens type
consisting of spherical glass lens, elements adhered to a synthetic resin and
encapsulated by a flexible, transparent waterproof plastic having a smooth
surface or as an unmetallized micro prismatic
reflective material element. The retro-reflective surface after cleaning with soap
and water and in dry condition shall have the minimum co-efficient of retro-

139
reflection (determined in accordance with ASTM 0:4956-09) as indicated in
Table 800-2.
Table 800-2 : Acceptable Minimum Co-efficient of Retro-Reflection
for High
Intensity Grade Sheeting (Type Ill) (Encapsulated Lens Type)
(Candelas Per Lux Per Square Metre)
Observati Entranc Whit Yello Orang Gree Re Blu Brow
on Angle e Angle e w e n d e n
in in
Degrees Degree
s
0.10B -40 300 200 120 54 54 24 14
0.10B -300 180 120 72 32 32 14 10
0 0
0.2 -4 250 170 100 45 45 20 12
0.20 -300 150 100 60 25 25 11 8.5
0 0
0.5 -4 95 62 30 15 15 7.5 5.0
0 0
0.5 -30 65 45 25 10 10 5.0 3.5
A minimum of Coefficient of Retro-reflection (RA)cd/fc/ft²(cd-
xl-1m²).
B Values for 0.1ᵒ observation angles are supplementary requirement
that shall apply only when specified by the purchaser in the Contract or order.
When totally wet, the sheeting shall show not less than 90 percent, of the
values of retro reflectance indicated in above Table. At the end of 7 years, the
sheeting shall retain at least 80 percent of its original retro-reflectance.

801.3.4 Prismatic Grade Sheeting

801.3.4.1 Prismatic Grade Sheeting (Type VIII)
The reflective sheeting shall be retro reflective sheeting made of micro
prismatic retro reflective material. The retro reflective surface, after cleaning
with soap and water and in dry condition shall have the minimum co-efficient
of retro reflection (determined in accordance with ASTM E 810) as indicated in
Table 800-4.

801.3.4.2 Prismatic Grade Sheeting (Type IX)

The reflective sheeting shall be retro-reflective sheeting made of micro
prismatic retro-reflective material. The retro-reflective surface, after cleaning
with soap and water and in dry condition shall have the minimum co-efficient
of retro-reflection (determined in accordance with ASTM E 810) as indicated in
Table 800-5.
Table 800-4: Acceptable Minimum Co-efficient of Retro-Reflection
for Prismatic Grade Sheeting (Type VIII) (Candelas Per Lux Per
Square Metre)

140
Obser Entran Whit Yello Orang Gree Re Blu Brow Fluor Fluor Fluor
vation ce e w e n d e n - - -
Angle Angle esce esce esce
in in nt nt nt
Degre Degre Yello Yello Oran
es es w/ w ge
Gree
n
0.1ᵒᴮ -4ᵒ 1000 750 375 100 150 45 30 800 600 300
0.1ᵒᴮ +30ᵒ 460 345 175 46 69 21 14 370 280 135
0.2ᵒ -4ᵒ 700 525 265 70 105 32 21 560 420 210
0.2ᵒ +30ᵒ 325 245 120 33 49 15 10 260 200 95
0.5ᵒ -4ᵒ 250 190 94 25 38 11 7.5 200 150 75
0.5ᵒ +30ᵒ 115 86 43 12 17 5 3.5 62 69 35

A Minimum Coefficient of Retro reflection (R^A) cd/fc/ft² (cd-Ix-

1m²).
B Values for 0.1ᵒ observation angles are supplementary requirements that
shall apply only when specified by the purchaser in the contract or order. When
totally wet, the sheeting shall show not less than 90 percent of the values of
retro reflection indicated in above Table. At the end of 10 years, the sheeting
shall retain at least 80 percent of its original retro-reflectance.

Table 800-5: Acceptable Minimum Co-efficient of Retro-Reflection

for Prismatic Grade Sheeting (Type IX) (Candelas Per Lux Per
Square Meter)
Observ Entra Whit Yell Oran Gree Re Blu Fluores Fluor- Fluor-
ation nce e ow ge n d e cent scent scent
Angle Angle Yellow/ Yellow Orange
in in Green
Degree Degre
s es
0.1ᵒᴮ -4ᵒ 600 500 250 66 13 130 530 400 200
0
0.1ᵒᴮ +30ᵒ 370 280 140 37 74 17 300 220 110
0.2ᵒ -4ᵒ 380 285 145 38 76 17 300 230 114
0.2ᵒ +30ᵒ 215 162 82 22 43 10 170 130 65
0.5ᵒ -4ᵒ 240 180 90 24 48 11 190 145 72
0.5ᵒ +30ᵒ 135 100 50 14 27 6.0 110 81 41
0.1ᵒ -4ᵒ 80 60 30 8.0 16 3.6 64 48 24
0.1ᵒ +30ᵒ 45 34 17 4.5 9.0 2.0 36 27 14

A Minimum Coefficient of Retro reflection (RA) cd/fc/ft² (cd-Ix- 1m²).

B Values for 0.1ᵒ observation angles are supplementary requirements that
shall apply only when specified by the purchaser in the contract or order. When

141
 totally wet, the sheeting shall show not less than 90 percent of the values of
retro reflection indicated in above Table. At the end of 10 years, the sheeting
shall retain at least 80 percent of its original retro-reflectance.

801.3.4.3 Prismatic Grade Sheeting (Type XI)

A Retro-reflective sheeting typically manufactured as a cube corner. The
reflective sheeting shall be retro-reflective sheeting made of micro prismatic
retro-reflective material. The retro-reflective surface, after cleaning with soap
and water and in dry condition shall have the minimum co-efficient of retro-
reflective (determined in accordance with ASTM E 810) as indicated in Table
800-6.

Table 800-5: Acceptable Minimum Co-efficient of Retro-Reflection

for Prismatic Grade Sheeting (Type IX) (Candelas Per Lux Per
Square Metre)
Obse Entran Whit Yell Oran Gree Re Blu Bro Fluores Fluo Fluor
rvati ce e ow ge n d e wn cent r- -
on Angle Yellow scen scent
Angle in /Green t Oran
in Degre Yell ge
Degr es ow
ees
0.1ᵒᴮ -4ᵒ 830 620 290 83 12 37 25 680 500 250
5
0.1ᵒᴮ +30ᵒ 325 245 115 33 50 15 10 260 200 100
0.2ᵒ -4ᵒ 580 435 200 58 87 26 1 460 350 175
0.2ᵒ +30ᵒ 220 165 77 22 33 10 7.0 180 130 66
0.5ᵒ -4ᵒ 420 315 150 42 63 19 13 340 250 125
0.5ᵒ +30ᵒ 150 110 53 15 23 7.0 5.0 120 90 45
0.1ᵒ -4ᵒ 120 90 42 12 18 5.0 4.0 96 72 36
0.1ᵒ +30ᵒ 45 34 16 5.0 7.0 2.0 1.0 36 27 14

A Minimum Coefficient of Retro reflection (RA) cd/fc/ft² (cd-Ix- 1m²).

B Values for 0.1ᵒ observation angles are supplementary requirements that
shall apply only when specified by the purchaser in the contract or order. When
totally wet, the sheeting shall show not less than 90 percent of the values of

142
retro reflection indicated in above Table. At the end of 10 years, the sheeting
shall retain at least 80 percent of its original retro-reflectance.

801.3.5 Adhesives
The sheeting shall have a pressure-sensitive adhesive of the aggressive-tack
type requiring no heat, solvent other preparation for adhesion to a smooth
clean surface, in a manner recommended by the sheering manufacturer. The
adhesive shall be protected by an easily removable liner (removable by peeling
without soaking in water or other solvent) and shall be suitable for the type of
material of the base plate used for the sign. The adhesive shall form a durable
bond to smooth, corrosion and weather resistant surface of the base plate such
that it shall not be possible to remove the sheeting from the sign base in one
piece by use of sharp instrument. The sheeting shall be applied in accordance
with the manufacturer’s specification.
801.3.6 Fabrication
Surface to be reflectorized shall be effectively prepared to receive the retro-
reflective sheeting. The aluminum sheeting shall be de-greased either by acid
or hot alkaline etching and all Traffic Signs, Marking and other Road
Appurtenances.
Scale/dust removed to obtain a smooth plain surface before the application of
retro-reflective sheeting. If the surface is rough, approved surface primer may
be used. After cleaning, metal shall not be handled, except by suitable device
or clean canvas gloves, between all cleaning and preparation operation and
application of reflective sheeting/primer. There shall be no opportunity for
metal to come in contact with grease, oil or other contaminants prior to the
application of retro-reflective sheeting. Complete sheets of the material shall
be used on the sings except where it is unavoidable. At splices, sheeting with
pressure-sensitive adhesives shall be overlapped not less than 5mm. Where
screen printing with transparent colors is proposed, only butt joint shall be
used. The material shall cover the sign surface evenly and shall be free from
twists, cracks and flods, Cut-outs to produce legends and broders shall be
bonded with the manner specified by the manufacturer.

801.3.7 Messages/Borders
The messages (legends, letter, numerals etc.) and borders shall either be
screen-printed or of cut out from durable transparent overlay or cut out from
the same type of reflective sheeting for the cautionary/mandatory sign boards.
Screen Printing shall be processed and finished with material and in a manner
specified by the sheeting manufacture. For the informatory and other sign
boards, the messages (legends, letters, numerals, etc.) and broders shall be
cut out from durable transparent overlay film or cut-out from the same
reflective sheeting only. Cut-outs shall be from durable transparent overlay
materials as specified by the manufacturer and shall be bonded with the
sheeting in the manner specified by the manufacturer. For screen-printed
transparent colored area on white sheeting, the co-efficient of retro-reflective
shall be less than 50 percent of the values of corresponding color in Table 800-
143
 2 to 800-8 as applicable. Cut-out messages and borders, wherever used, shall
be either made out of retro-reflective sheeting or made out of durable
transparent overlay except those in black which shall be of non- reflective
sheeting or opaque in case of durable transparent overlay.

801.3.8 Color for Signs

801.3.8.1 Signs shall be provided with retro-reflective sheeting and or
overlay film screening ink. The reverse side of all signs shall be painted grey.
801.3.8.2 Except in the case of railway level crossing signs the sign posts
shall be painted in 250mm side bands , alternately black and white . The lowest
band next to be ground shall be in black.
801.3.8.3 The color of the material shall be located within the area
defined by the chromaticity coordinates in Table 800-7 and comply with the
luminance factor when measured as per ASTM D-4956.

Table 800-5: Colour Specified Limits (Daytime)

Daytime
Colour 1 2 3 4 Luminance
Factor(Y%)

x y x y x y x y Min. Max.
White 0.303 0.300 0.368 0.366 0.340 0.3939 0.274 0.329 15 --
Yellow 0.498 0.412 0.557 0.442 0.479 0.520 0.438 0.472 24 45
Green 0.026 0.399 0.166 0.364 0.286 0.446 0.207 0.771 2.5 11
Red 0.648 0.351 0.35 0.265 0.629 0.281 0.565 0.346 2.5 11
Blue 0.140 0.035 0.244 0.210 0.190 0.255 0.065 0.216 1 10
Orange 0.558 0.352 0.636 0.364 0.570 0.429 0.506 0.404 12 30
Brown 0.430 0.340 0.610 0.390 0.550 0.450 0.430 0.390 1 6
Fluorescent 0.387 0.610 0.369 0.546 0.428 0.496 0.460 0.540 60 --
Yellow-Green
Fluorescent 0.479 0.520 0.446 0.483 0.512 0.421 0.557 0.442 45 --
Yellow
Fluorescent 0.583 0.416 0.535 0.400 0.595 0.351 0.645 0.355 25 --
Orange

The colour shall be durable and uniform in acceptable hue when viewed in day
light or under normal headlights at night.
801.3.8.4 The Regulatory/Prohibitor and warning signs shall be provided with
white background and red border. The legend/symbol for these signs shall be
in black colour. The Mandatory sign shall be provided with Blue background
and white Symbol/letter.
801.3.8.5 The colours chosen for informatory or guide sings shall be distinct
for different classes of roads. For National Highways, these signs shall be of

144
 green background and for Expressways these signs shall be of blue background
with white border, legends and word messages.

801.3.9 Refurbishment
Where existing signs are specified for refurbishment, the sheeting shall have a
semi-rigid aluminum backing or materials as per Clause 801.2.5,per-coated with
aggressive-tack type pressure sensitive adhesive. The adhesive shall be suitable
for the type of material used for the sign and should thoroughly bond with that
material.

801.3.9 Sizes of Letters

801.3.10.1 Letter size should be chosen with due regard to the speed,
classification and location of the road, so that the sign is of adequate size for
legibility but without being too large or obtrusive. The size of the letter, in terms
of x-height, to be chosen as per the design speed is given in Table 800-8

Table 800-8: Acceptable Limits for Sizes of Letters

The thickness of the letters and their relation to the x-heights are indicated in
Design Minimum ‘x’Height Minimum Sight Minimum
Speed of the letters Distance/Clear Distance from
(Km./hr.) (mm) Visibility Distance Center Line (m)
(m)
40 100 45 12
50 125 50 14
65 150 60 16
80 250 80 21
100 300 90 24
120 400 115 32
Table IV (a) of the Annexure-4 of IRC:67 to facilitate the design of the
informatory signs and definition plates.
801.3.10.2 For advance direction signs on non-urban roads, the letter size
(‘x’ height) should be minimum of 150 mm for Expressway, National and State
Highways and 100 mm for other roads. In case of overhead signs, the size (‘X’
height) of letters may be minimum 300 mm. Thickness of the letter could be
varied from 1/6 to 1/5 of the letter ‘x’ size. The size of the initial uppercase
letter shall be 1-1/3 times x-height. In urban areas, letter size shall be 100 mm
on all directional signs. For easy and better comprehension, the word message
shall be written in upper case letters only.
801.3.10.3 Letter size on definition plates attached with normal sized signs
should be 100 mm or 150 mm. In the case of small signs, it should be 100 mm.
Where the message id long, as for instance in “NO PARKING” and “NO
STOPPING” signs, the message may be broken into two lines and size of letters
may be varied in the lines so that the definition plate is not too large. The
lettering on definition plates will be in upper case letters.

145
801.3.11 Warranty and Durability
The Contractor shall obtain from the manufacturer a ten year warranty for
satisfactory field performance including stipulated retro-reflectance of the retro-
reflectance sheeting of micro-prismatic sheeting and a seven-year warranty for
high intensity grade and submit the same to the Engineer. The warranty shall
be inclusive of the screen printed or cut out letters/legends and their bonding
to the retro-reflective sheeting. The Contractor/supplier shall also furnish the
LOT numbers and certification that the signs and materials supplied against the
assigned work meets all the stipulated requirements and carry the stipulated
warranty and that the contractor/supplier is the authorized converter of the
particular sheeting.
All signs shall be dated during fabrication with indelible markings to indicate
the start of warranty. The warranty shall also cover the replacement obligation
by the sheeting manufacturer as well as contractor for replacement
repair/restoration of the retro-reflective efficiency.
A certificate in original shall be given by the sheeting manufacturer that its
offered retroreflective sheeting has been tested for various parameters such as
co-efficient of retroreflection, day/night time colour and luminance, shrinkage,
flexibility, linear removal, adhesion, impact resistance, specular gloss and
fungus resistance; the tests shall be carried out by a Government Laboratory
in accordance with various ASTM procedures and the results must show that
the sheeting has passed the requirements for all the above mentioned
parameters. A copy of the test reports shall be attached with the certificate.
801.4 Installation
801.4.1 The traffic signs shall be mounted on support posts, which may be of
Gl pipes conforming to IS:1239, Rectangular Hollow Section conforming to
IS:4923 or Square Hollow Section conforming to IS:3589. Sign posts, their
foundations and sign mountings shall be so constructed as to hold these in a
proper and permanent position against the normal storm wind loads or
displacement by vandalism. Normally, signs with an area up to 0.9 sq.m shall
be mounted on a single post, and for greater area two or more supports shall
be provided. Post-end(s) shall be firmly fixed to the ground by means of
properly designed foundation. The work of foundation shall conform to relevant
Specifications as specified.
801.4.2 All components of signs (including its back side) and supports, other
than the reflective portion and G. I. posts shall be thoroughly de-scaled,
cleaned, primed and painted with two coats of epoxy/ fibre glass/ powder
coated paint. Any part of support post below ground shall be painted with
protective paint.
801.4.3 The signs shall be fixed to the posts by welding in the case of steel
posts and by bolts and washers of suitable size. After the nuts have been
146
tightened, the tails of the bolts shall be furred over with a hammer to prevent
removal.
801.5. Measurements for Payment The measurement of standard
cautionary, mandatory and information signs shall be in numbers of different
types of signs supplied and fixed, while for direction and place identification
signs, these shall be measured by area in square metres.
A warranty for 7 years for the retro reflective sheeting from original
manufacturer and certified copy of three years outdoor exposure test report
from third party test lab for the product offered shall be submitted by
contractor.
801.6. Rate The Contract unit rate shall be payment in full for the cost of
making the road sign, including all materials, installing it at the site and
incidentals to complete the work in accordance with the Specifications.

Item No.30: - Facility Informatory Sign :-Providing and fixing sign

boards made out of 2mm aluminium sheet / 4mm ACP (Aluminum
composite Panel); size 80 x 60 cms rectangular as per design of IRC-
67-2012. Pre treated with phospheting process & acid etching; coated
with one coat of epoxy primer and two coats of best quality epoxy
paint ;reflectorised with Micro Prismatic Grade retro
refiectivesheeting of Type-11 as per ASTM D-4956 and latest
M.O.S.T.Specifications; 3.6mtr long stand post of 75 x 75 x 6mm /
65NB Circular MS Pipe as required and frame fabricated from suitable
size iron angle of 35 x 35 x 3mm; painted with bestquality epoxy
coatings in black and white bends. The details of symbol foreach
board shall be as per theinstruction of engineer in charge. The fixing
at site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each
leg.including excavation, curing etc.complete under the supervision
of engineer in charge. A warranty for 10 years for the Retro reflective
sheeting from original manufacturer & a certified copy of 3 year
outdoor exposure test report from third party test lab for the product
offered shall be submitted by contractor. (A) Class-C Type-11 Retro
Reflective sheeting.
This work shall consist of Providing and fixing Facility Informatory Sign Board
and shall be carried out as per relevant detailed specification of Item No. 29
of this contract.

801.5. Measurements for Payment

The measurement of standard Informatory sign shall be in numbers of

different types of signs supplied and fixed, while for direction and place
identification signs. A warranty for 7 years for the retro reflective sheeting from
original manufacturer and certified copy of three years outdoor exposure test

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report from third party test lab for the product offered shall be submitted by
contractor.

801.6. Rate
The Contract unit rate shall be payment in full for the cost of making the road
sign, including all materials, installing it at the site and incidentals to complete
the work in accordance with the Specifications.

Item No.31: - Regulatory / Mandatory Sign :-Providing and fixing sign

boards made out of 2mm aluminium sheet / 4mm ACP (Aluminum
composite Panel); size 60 cms Dia Circle as per design of IRC-67-
2012. Pre treated with phospheting process & acid etching; coated
with one coat of epoxy primer and two coats of best quality epoxy
paint ;reflectorised with Micro Prismatic Grade retro
refiectivesheeting of Type-11 as per ASTM D-4956 and latest
M.O.S.T.Specifications; 3.6mtr long stand post of 75 x 75 x 6mm /
65NB Circular MS Pipe as required and frame fabricated from suitable
size iron angle of 35 x 35 x 3mm; painted with bestquality epoxy
coatings in black and white bends. The details of symbol foreach
board shall be as per theinstruction of engineer in charge. The fixing
at site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each
leg.including excavation, curing etc.complete under the supervision
of engineer in charge. A warranty for 10 years for the Retro reflective
sheeting from original manufacturer & a certified copy of 3 year
outdoor exposure test report from third party test lab for the product
offered shall be submitted by contractor. (A) Class-C Type-11 Retro
Reflective sheeting.
This work shall consist of Providing and fixing Regulatory / Mandatory Sign
Board and shall be carried out as per relevant detailed specification of Item
No. 29 of this contract.

801.5. Measurements for Payment

The measurement of standard Regulatory/Mandatory sign shall be in numbers

of different types of signs supplied and fixed, while for direction and place
identification signs. A warranty for 7 years for the retro reflective sheeting from
original manufacturer and certified copy of three years outdoor exposure test
report from third party test lab for the product offered shall be submitted by
contractor.

801.6. Rate
The Contract unit rate shall be payment in full for the cost of making the road
sign, including all materials, installing it at the site and incidentals to complete
the work in accordance with the Specifications.
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Item No.32: - Chevron sign :-Providing and fixing sign boards made
out of 1.5mm aluminium sheet / 3mm ACP (Aluminum composite
Panel); size 60x50 cm as per design of IRC-67-2012. Pre treated with
phospheting process & acid etching; coated with one coat of epoxy
primer and two coats of best quality epoxy paint ;reflectorised with
Micro Prismatic Grade retro refiectivesheeting of Type-11 as per
ASTM D-4956 and latest M.O.S.T.Specifications; 3.3 mtr long stand
post of 75 x 75 x 6mm / 65NB Circular MS Pipe as required and frame
fabricated from suitable size iron angle of 50 x 50 x 5mm; painted
with bestquality epoxy coatings in black and white bends. the details
of symbol or inscription / numerals for each board shall be as per the
instruction of engineer in charge.The fixing at site shall be in 1:2:4 CC
blockof size 45 x 45 x 60 Cms. for each leg.including excavation,
curing etc.complete under the supervision of engineer in charge. A
warranty for 10 years for the Retro reflective sheeting from originaa
manufacturer & a certified copy of 3 year outdoor exposure test
report from third party test lab for the product offered shall be
submitted by contractor. (A) Class-C Type-11 Retro Reflective
sheeting.

This work shall consist of Providing and fixing Chevron Sign Board and shall be
carried out as per relevant detailed specification of Item No. 29 of this
contract.

801.5. Measurements for Payment

The measurement of standard Chevron sign shall be in numbers of different

types of signs supplied and fixed, while for direction and place identification
signs. A warranty for 7 years for the retro reflective sheeting from original
manufacturer and certified copy of three years outdoor exposure test report
from third party test lab for the product offered shall be submitted by
contractor.

801.6. Rate
The Contract unit rate shall be payment in full for the cost of making the road
sign, including all materials, installing it at the site and incidentals to complete
the work in accordance with the Specifications.

Item No.33: - Hazard Marker Sign :-Providing and fixing sign boards
made out of 2.0 mm aluminium sheet / 4 mm ACP (Aluminum
composite Panel); size 90x30 cms. rectangular as per design of IRC-
67-2012. Pre treated with phospheting process & acid etching; coated
with one coat of epoxy primer and two coats of best quality epoxy
paint ;reflectorised with Micro Prismatic Grade retro
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refiectivesheeting of Type-11 as per ASTM D-4956 and latest
M.O.S.T.Specifications; 1.8mtr long stand post of 75 x 75 x 6mm /
65NB Circular MS Pipe as required and frame fabricated from suitable
size iron angle of 35 x 35 x 3mm; painted with bestquality epoxy
coatings in black and white bends. The details of symbol foreach
board shall be as per theinstruction of engineer in charge. The fixing
at site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each
leg.including excavation, curing etc.complete under the supervision
of engineer in charge. A warranty for 10 years for the Retro reflective
sheeting from original manufacturer & a certified copy of 3 year
outdoor exposure test report from third party test lab for the product
offered shall be submitted by contractor. (A) Class-C Type-11 Retro
Reflective sheeting
This work shall consist of Providing and fixing Hazard Marker Sign Board and
shall be carried out as per relevant detailed specification of Item No. 29 of
this contract.
801.5. Measurements for Payment

The measurement of standard Hazard Marker sign shall be in numbers of

different types of signs supplied and fixed, while for direction and place
identification signs. A warranty for 7 years for the retro reflective sheeting from
original manufacturer and certified copy of three years outdoor exposure test
report from third party test lab for the product offered shall be submitted by
contractor.

801.6. Rate
The Contract unit rate shall be payment in full for the cost of making the road
sign, including all materials, installing it at the site and incidentals to complete
the work in accordance with the Specifications.

Item No.34: - Providing and fixing pre-cast concrete kerb stone of

gray cement based concrete block 30cm length,30cm height and
15cm thick of M25 grade concret as per approved design and
including excavation for fixing in proper line and level,filling the joint
with C:M 1:3 (1cement:3 fine sand) etc complete.

1. Description

The work shall consist of scarifying the existing road surface to required depth,
preparing pre cast kerb with kerb laying machine of required shape and size
and fixing them in place in traffic island at Junction or as directed; as per
drawing and joining them in C.M.1:3 and filling the central island portion with

150
selected soil and compacting it and painting the sides as directed.
2. Material:

2.1: M-25 Pre Cast Kerb: (1) Water shall confirm to M-1 (2) Cement shall
conform to M-3 (3) Sand shall conform to M-6 (4) Mortar shall conform to M-
11 (5) Aggregates shall conform to M-12 (6) Shuttering shall conform to M-26.

Pre cast C.C. Block: M25 Precast block shall be sharp, smooth and in true
line, level and shape as per drawing or as directed. Expansion joint shall be
provided at every 10 mt. length

3.Construction:
The road surface shall be excavated to required depth on approved alignment.
For the base of stone C.C. 1:5:10 base concrete shall be provided
conforming to Standard Specification The vertical C.C. stones shall be fixed
as shown in drawing to line and level and expansion joint shall be provided.
The outer sides of the vertical kerb stones shall be applied a coat of primer
and subsequently white washed with two coats

Mode of Measurement and Payment: The measurement shall be on

running metre basis and shall include all the work including necessary
excavation, C.C. Blocks and soil filling and joining C.C. Blocks in C.M.1:3,
curing, white washing , with all labour, material tools & plants etc complete.
sides exposed at right angles to each other. The surface touching the wall may
not be planed unless it is required in order to straighten up the member or to
obtain the overall size within the tolerances specified.
Item No.35: Portable Barricade in Construction Zone (Installation of a steel
portable barricade with horizontal rail 300 mm wide, 2.5 m in length fitted
on a 'A' frame made with 45 x 45 x 5 mm angle iron section, 2.0 m in height,
horizontal rail painted (2 coats) with yellow and white stripes, 150 mm in
width at an angle of 450, 'A' frame painted with 2 coats of yellow paint,
complete as per IRC:SP:55-2001 ) including Blinkers,Retro reflective
film/sticker. All material of barricading which is use while working will be
property of contractor after completion of entire work.
813.6 Barricades

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The barricades may be temporary or permanent. Barricades may be of wooden, metal
or other suitable material panels. They shall be stable under adverse weather
conditions and appear significant but not to cause damage to the vehicle if they are
stuck. Because of their vulnerable position and the hazard they could create, they
should be constructed of lightweight materials and should have no rigid stay bracing
for A-frame designs.

The rail/panel length shall be 3000 mm. The width of rails shall be 200 mm to 300
mm. The rails shall be painted in alternate yellow and white stripes of 150 mm width
each, sloping away at an angle of 45° in the direction of traffic. The support shall be
on a "A-Configuration" or otherwise at the top to permit convenient folding and staking
for transportation. Their stability shall be improved by ballasting. On highways or in
other situations where barricades may be susceptible to overturning in the wind,
sandbags shall be used for ballasting. Sandbags may be placed on lower parts of the
frame or stays to provide the required ballast but shall not be placed on top of any
striped rail. Barricades shall not be ballasted by heavy objects such as rocks or chunks
of concrete.

813.6.3 Application

813.6.3.1 barricades shall be used in situations where traffic is maintained through

the temporary traffic control zone. They may be used singly or in groups to mark a
specific condition, or they may be used in a series for channelizing traffic.
When a highway is legally closed but access must still be allowed for local traffic, the
barricade should not be extended completely across a roadway. A sign with the
appropriate legend concerning permissible use by local traffic shall be mounted.
Signs may be erected on barricades, particularly those of the fixed type, that offer a
most advantageous facility for this purpose. The ROAD CLOSED and DETOUR or
ARROW signs, and the large arrow warning signs, for example, can be mounted
effectively on or above the barricade that closes the roadway.

813.7 Longitudinal Safety Barriers

813.7.1 Longitudinal channelising barricades are light weight channelising devices

that can be used barricades, or connected so that they are highly visible and have
good target value. They should be interlocked to delineate or channelise the traffic
flow and mark the work zone. The inter-locking barricade wall should not have gaps
that allow pedestrians or vehicles to stray from the channelising path. Longitudinal
channels barricades are located adjacent to traffic and therefore, are subject to impact
by errant vehicles. Because of their vulnerable positions, longitudinal channelising
barricades should be constructed of light weight materials and be crash worthy. They
shall be of high density polyethylene, non-fading, and high impact and U.V. resistant.
They shall be of orange, white or custom colours. Their size should be minimum 1500
mm in length, 3000 mm in height. They could be filled with water through an aperture
on the top and emptied by removing a plug at the base.

On roads with low speed traffic, Gl sheets material could be considered for longitudinal
barricades. They shall be firmly secured to vertical support system with no sharp
edges to pose any hazard when struck.

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Precoated galvanized iron profile sheets shall be of approved make and shade having
0.50 mm (+0.05%) total coated thickness with zinc coating as per IS- 277, in 550
Mpa steel grade, 5-7 microns epoxy primer on both side of the sheet and polyester
top coat 15-18 microns. Their configuration shall be as per the drawing or as directed
by the Engineer.

813.7.2 Mode of Measurement and Payment: Measurement & payment shall be

per Running metre of longitudinal barrier and payment for the running metre of
complete job of providing, installation and maintenance including credit of material at
site as per the direction of the Engineer.

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