STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

SECTION 2000 – CONCRETE FOR STRUCTURES

2001 SCOPE

This Section covers the materials, design of mixes, transport, placing, compaction and
curing of concrete and mortar required in the works. It also covers reinforcement for
concrete.
2002 DEFINITIONS
Structural concrete is any class of concrete which is used in reinforced, pre-stressed or
unreinforced concrete construction which is subject to stress.
Non-structural concrete is composed of materials complying with the Specification but for
which no strength requirements are specified and which is used only for filling
foundations and similar purpose where it is not subjected to significant stress.
A pour refers to the operation of placing concrete into any mould, bay or formwork, etc.
and also to the volume which has to be filled. Pours in vertical succession are referred to
as lifts.
2003 MATERIAL FOR CONCRETE
(1) General
The Contractor shall submit to the Engineer full details of all materials which he
purposes to use for making concrete. No concrete shall be placed in the works until
the Engineer has approved the materials of which it is composed. In accordance with
Clause 603, approved materials shall not thereafter be altered or substituted by other
materials without the consent of the Engineer.
(2) Cement
Cement shall comply with the requirements of Clause 614.
Cement shall be free flowing and free of lumps. It shall be supplied in the
manufacturer’s sealed unbroken bags or in bulk. Bagged cement shall be transported
in vehicles provided with effective means of ensuring that it is protected from the
weather.
Bulk cement shall be transported in vehicles or in containers built and equipped for
the purpose.
Cement in bags shall be stored in a suitable weatherproof structure of which the
interior shall be dry and well ventilated at all times. The floor shall be raised above
the surrounding ground level not less than 30 cm and shall be so constructed that no
moisture rises through it.
Each delivery of cement in bags shall be stacked together in one place. The bags
shall be closely stacked so as to reduce air circulation with min gap of 500 mm from
outside wall. If pallets are used, they shall be constructed so that bags are not
damaged during handling and stacking. Stack of cement bags shall not exceed 8 bags
in height. Different types of cement in bags shall be clearly distinguished by visible

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marking and shall be stored in separate stacks.

Cement form broken bags shall not be used in the works. Cement in bags shall be
used in the order in which it is delivered.
Bulk cement shall be stored in weather proof silos which shall bear a clear indication
of the type of cement contained in them. Different types of cement shall not be
mixed in the same silo.
The Contractor shall provide sufficient storage capacity on site to ensure that his
anticipated programme of work is not interrupted due to lack of cement.
Cement which has become hardened or lumpy or fails to comply with the
Specification in any way shall be removed from the Site.
All cement for any one structure shall be from the same source as far as possible.
All cement used in the works shall be tested by the manufacturer. The manufacturer
shall provide the results of tests as given in Table 6.6 for each supply and for the last
six months of his production.
Each set of tests carried out by the manufacturer on samples taken from cement
which is subsequently to site shall relate to no more than one day’s output of each
cement plant.
The Contractor shall constitute each type of cement and not less than as specified in
Table 5.2, representative samples to be tested when instructed by the Engineer in a
laboratory acceptable to him, in case of the concrete mixes do not comply with the
requirements of this Specification.
Cement which is stored on site for longer than one month shall be tested in such
laboratory for every 200 tons or part thereof and at monthly intervals thereafter.
The Contractor shall keep full records of all data relevant to the manufacture,
delivery, testing and the cement used in the works and shall provide the Engineer
with two copies thereof.
(3) Fine Aggregate
Fine aggregate shall be clean hard and durable and shall be natural sand, crushed
gravel sand or crushed rock sand complying with IS 383. All the material shall
be in accordance Table 20.1.
Table 20.1 Grading Requirement for fine aggregate
IS sieve designation (mm) Percentage passing
10 100
4.75 90-100
2.36 75-100
1.18 55-90
0.60 35-59
0.30 8-30
0.15 0-10

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In order to achieve an acceptable grading, it may be necessary to blend materials

from more than one source. The deviation from the initial fineness modulus shall be
no more than ± 0.30 for ordinary concrete and ± 0.20 for high quality concrete.

However, in respect of the presence of deleterious materials the fine aggregate shall
not contain iron pyrites, iron oxides, mica, shale, coal or other laminar soft or porous
materials or organic matter unless the Contractor can show by comparative tests on
finished concrete as set out in Clause 617 and as per the direction of the Engineer,
that presence of such materials does not affect the properties of the concrete.
(4) Coarse Aggregate
Coarse aggregate shall be clean hard and durable crushed rock, crushed gravel or
natural gravel. Coarse aggregate shall be supplied in the nominal size called for in
the contract and shall be of the grading as specified in Table 20.2.
Table 20.2 Grading Requirement for Coarse Aggregate
IS Percentage Passing for Single Sized Aggregate Percentage Passing for Graded
sieve of nominal Size Aggregate of Nominal Size
S.N
Design 63 40 20 16 12.5 10 40 20 16 12.5
ation mm mm mm mm mm mm mm mm mm mm
i) 80 mm 100 100
85-
ii) 63 mm 100
100
85- 90-
iii) 40 mm 0-30 100 100
100 100
85- 90-
iv) 20 mm 0-5 0-20 100 30-70 100 100
100 100
85- 90-
v) 16 mm 100
100 100
12.5 85- 90-
vi) 100
mm 100 100
85-
vii) 10 mm 0-5 0-5 0-20 0-30 0-45 10-35 25-35 30-70 40-85
100
viii 4.75
0-5 0-5 0-10 0-5 0-10 0-10 0-10
) mm
2.36
ix)
mm
Other properties shall be set out below:
Combined Flakiness and Elongation Index :Flakiness and elongation shall be
determined in accordance with IS 2386 (Part 1) on the same sample. After carrying
out the flakiness index test, the flaky material shall be removed from the sample and
the remaining portion shall be used for carrying out elongation index. Indices so
worked out shall be added numerically to give combined flakiness and elongation
index. The combined flakiness and elongation index so obtained shall not exceed 40
percent for uncrushed or crushed aggregate.
Water Absorption: the aggregate shall not have a water absorption of more than 2
per cent when tested as set out in IS: 2386 Part 3.
Los Angeles Abrasion (LAA): The aggregate shall have LAA not more than 45% for

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ordinary concrete, and not more than 35% for high quality concrete, when tested in
accordance with IS: 2386 Part 4.
Aggregate Crushing Value (ACV): The aggregate shall have ACV not more than
30% for pavement structure and not more than 45% for other structure when tested
in accordance with IS: 2486 Part 4.
Alkali Aggregate Reactivity: The aggregate shall comply with IS 456 when tested in
accordance with IS:386 Part 7.
(5) Testing Aggregate
(a) Acceptance Testing
The Contractor shall deliver to the Engineer samples containing not less than 50 kg
of any aggregate which he proposed to use in the works and shall supply such further
samples as the Engineer may require. Each sample shall be clearly labeled to show
its origin and shall be accompanied by all information called for in IS: 2386 Part 1 to
8.
Tests to determine compliance of the aggregates with the requirements of sub-clause
2003 (3) and (4) shall be carried out by the Contractor in a laboratory acceptable to
the Engineer. If the tested materials fail to comply with the Specification, further
tests shall be made in the presence of the Contractor and the Engineer. Acceptance of
the material shall be based on the results of such tests.
All the materials shall be accepted if the results of not less than three consecutive
sets of test executed in accordance with IS 2386 (Part 1-8) show compliance with the
Sub-clause 2003 (3) and (4).
(b) Compliance Testing/Process Control Testing
The Contractor shall carry out routine testing of aggregate for compliance with the
Specification during the period that concrete is being produced for the works.
Frequency test shall be as follows:
Material Test Test procedure Frequency
Fine aggregate and Grading IS: 2386 Part 1 1 set ( 3 nos ) test for
Silt,Clay each 10 to 50 cum and
Contents and IS: 2386 Part2 additional test for each
Organic 50 cum of concrete
Impurities
Coarse Aggregate GradingSilt, IS: 2386 Part 1 1 set ( 3 nos ) test for
Clay Contents IS: 2386 Part2 each 25 to 125 cum and
and Organic additional test for each
Impurities 125 cum
If the aggregate from any source is variable, the frequency of testing shall be
increased as instructed by the Engineer. Chloride Content: As frequently as may be
required to ensure that the proportion of chlorides in the aggregates does not exceed
the limit stated in the Specification.

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Sulphate Content and Alkali Aggregate Reactivity: As frequently as may be required

according to the variability of sulphate content and alkali reactivity assessed from the
laboratory test carried out during the concrete mix design.
(6) Delivery and Storage of Aggregate
Aggregate shall be delivered to site in clean and suitable vehicles. Different type or
sizes of aggregate shall not be delivered in one vehicle.
Each type or size of aggregate shall be stored in a separate bin or compartment
having a base such that the contamination of aggregate is prevented. Dividing walls
between bins shall be substantial and continuous so that no mixing of types or sizes
occurs.
The storage of aggregate shall be arranged in such a way that drying out in hot
weather is prevented in order to avoid fluctuations in water content. Storage of fine
aggregates shall be arranged in such way that they can drain sufficiently before use
in order to prevent fluctuations in water content of the concrete.
(7) Water for Concrete Mortar
Water shall be reasonably clear and free from injurious amounts of oils, acids,
alkalis, salts, sugar, organic materials or other substances that may deleterious to
concrete or steel.
The Contractor shall carry out tests in compliance with IS 456 to establish
compliance with Specifications.
(8) Admixture
(a) General
The use of admixtures in concrete may be required under the contract to promote
special properties in the finished concrete or may be proposed by the Contractor to
assist him in compliance with the Specification.
In all cases the Contractor shall submit to the Engineer full details of the admixture
he proposes to use and the manner in which he proposes to add it in the mix. The
information provided shall include:
(i) The typical dosage, the method of dosing, and the detrimental effects of an
excess or deficiency in the dosage.
(ii) The chemical names of the main active ingredients in the admixture.
(iii) Whether or not the admixture contains chlorides, and if so the chloride ion
content expressed as a percentage by weight of admixture.
(iv) Whether the admixture leads to the entrainment of air when used at the
manufacturer’s recommended dosage, and if so the extent to which it does so.
(v) Details of previous uses of the admixture in Nepal.
Admixture/additives conforming to IS 9103 may be used subject to approval of the
Engineer. However, admixture/ additives generating hydrogen or nitrogen and
containing chlorides, nitrates, sulphides, sulphates or any other material likely to

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adversely affect the steel or concrete shall not be permitted.

Compatibility of the admixtures with the cement and any other pozzolan or hydraulic
addition shall be ensured by for avoiding the following problems.
(i) Requirement of large dosage of superplasticizer for achieving the desired
workability.
(ii) Excessive retardation of setting
(iii) Excessive entrainment of large bubbles
(iv) Unusually rapid stiffening of concrete
(v) Rapid loss of slump
(vi) Excessive segregation and bleeding
(9) Curing Material
Curing material shall be moist curing or membrane curing . Approved curing
compound may be used , which shall be applied to all exposed surface of the
concrete as soon as possible after the concrete has set. Impermeable membrane such
as polythene sheeting covering closely the concrete surface may also be used to
provide effective barrier against evaporation

2004 DESIGN OF CONCRETE MIXES

(1) Classes of Concrete
The classes of structural concrete to be used in the works shall be as shown on the
Drawing. Where sufficient test results for a particular grade of concrete are not
available, the value of standard deviation given in Table 8 of IS 456: 2000 may be
assumed for design of mix in the first instance for the structure other than Bridges.
As soon as the results of samples are available, actual calculated standard deviation
shall be used and the mix designed properly for reference Table 20.3a may be used,
in which the class designation includes two figures. The first figures indicate the
2
characteristic strength fck at 28 days expressed in N/mm and the second figure is the
maximal nominal size of aggregate in the mix expressed in millimeters. Letter M in
the class designation stands for Mix, letter SM stand for Special Mix.
Consistence of the mix, assessed through the Slump Test where the slump is
measured in millimeters, is designate as follows:
S: Stiff consistence, for slump ≤40
P: Plastic consistence, for slump >40 and ≤90
VP: Very Plastic consistence, for slump >90 and ≤150
F: Flowing consistence for slump >150

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Table 20.3a: Concrete Classes and Strength

Classes of Consi Type of Characteri Maximum Trial mixes Early works test cubes Concrete
Concrete st- uses stic Nominal Minimal Target Any one Average of mix
ence Strength Sizeof Strength result 3
fck Aggreg fck=fck + 1.65*s (N/mm2) consecutive
(N/mm2) ate mm (N/mm2) results
(N/mm2)
M 10/75 S Ordinary 10 75 16 7 14

Designed /
Prescribed
M 10/40 S Ordinary 10 40 16 7 14
M 15/20 S Ordinary 15 20 21 12 19
M 15/40 S Ordinary 15 40 21 12 19
M 20/20 S Ordinary 20 20 27 16 24
M 20/40 S Ordinary 20 40 27 16 24
M 25/20 S Ordinary 25 20 32 21 29

Designed
M 25/40 S Ordinary 25 40 32 21 29
M 30/40 S High Quality 30 40 38 26 34
M 30/20 P High Quality 30 20 38 26 34
M 30/12 P High Quality 30 12 38 26 34
M 35/40 P High Quality 35 40 43 31 39
M 35/20 P High Quality 35 20 43 31 39
M 40/20 P High Quality 40 20 48 36 44
M 45/20 P High Quality 45 20 53 41 49
M 50/20 P High Quality 50 20 58 46 54
M 55/20 P High Quality 50 20 63 51 59

Designed
SM 30/40 VP Underwater 30 40 38 26 34
SM 30/20 P Underwater 30 20 38 26 34
SM 30/20 F Bored Piles 30 20 38 26 34
SM 40/20 S Precast Piles 40 20 48 36 44

Table 20.3b:
Concrete Classes and Strength (For Bridges/Flyover/Underpass)
Classes of Consi Type of Characteri Maximum Trial mixes Early works test cubes
Concrete mix

Concrete st- uses stic Nominal Minimal Target Any one Average of
ence Strength Size of Strength result 3
fck Aggreg (N/mm2) (N/mm2) consecutive
(N/mm2) ate mm results
(N/mm2)

M 25/20 S Ordinary 25 20 35 21 29
M 30/20 P High Quality 30 20 40 26 34
Designed

M 30/12 P High Quality 30 12 40 26 34

M 35/20 P High Quality 35 20 45 31 39
M 40/20 VP High Quality 40 20 50 36 44
M 45/20 VP High Quality 45 20 56 41 49
Designed

M 45/12 F High Quality 45 12 56 41 49

M 50/20 P High Quality 50 20 61 46 54
M 50/20 F High Quality 50 20 61 46 54
M 55/20 P High Quality 50 20 61 51 59

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

SM 30/40 VP Underwater 30 40 40 26 34
SM 30/20 P Underwater 30 20 40 26 34
SM 30/20 F Bored Piles 30 20 40 26 34
SM 40/20 S Precast Piles 40 20 50 36 44
Post-
tensioned
SM 45/20 VP Structures 45 20 56 41 49
Post-
tensioned
Structures
SM 45/12 F 45 12 56 41 49
Post-
tensioned
Structures

Designed
SM 50/20 VP 50 20 61 46 54
Post-
tensioned
Structures
SM 50/12 F 50 12 61 46 54
Post-
tensioned
Structures
SM 60/20 VP 60 20 72 56 64

(2) Design of Proposed Mixes

Concrete mixes shall comply with Clause 617.
The contractor shall design all the concrete mixes called for in the Drawing using the
ingredients which have been approved by the Engineer in accordance with Clause
2003 and in compliance with the following requirements:
(a) The aggregate portion shall be well graded from the nominal maximum size of
stone down to the 150-micron size.
(b) The cement content shall be such to achieve the strength called for in Table
20.3 but in any case not less than the minimum necessary as shown in Table
20.4.
(c) The workability shall be consistent with ease of placing and proper compaction
having regard to the presence of reinforcement and other obstructions.
(d) The water/cement ratio shall be the minimum consistent with adequate
workability but in any case not greater than 0.5 for classes of concrete higher
than M20 taking due account of any water contained in the aggregates. The
Contractor shall take into account that this requirement may in certain cases
require the inclusion of a workability agent in the mix.
(e) For each class of concrete Contractor shall conduct laboratory trial as
mentioned in 2004(3) based on the results of these trials the contractor shall
submit full details of his proposal including the result of test to the Engineer
for approval. However, Engineer’s approval shall not relieve the contractor
from his responsibilities for compliance with these specifications.
(f) The cement content shall not more than 450 kg/ m3 unless special

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consideration has been given in design to cover the risk of cracking due to
drying and shrinkage in thin sections or to early thermal cracking and to the
increased risk of damage due to alkali silica reactions.
Table 20.4: Minimum Cement Content and Maximum water cement ratio

SN Exposure Minimum cement Maximum free Minimum

content in kg/ water cement Grade of
cu.m. ratio Concrete
A. Plain Cement concrete
1 Mild 220 0.6
2 Moderate 240 0.6 M15
3 Severe 250 0.5 M20
B. Reinforced Cement concrete
1 Mild 300 0.55 M20
N
ote:
1.The minimum cement contents shown in the above table are required in order to achieve
impermeability and durability having 20 mm size aggregate, in case of 10 mm size add 40 kg/ m3 and
in case of 40 mm size aggregate reduce upto 30 kg / m3. In order to meet the strength requirements in
the Specification higher contents may be required.
2. Exposure can classified as
Mild: Concrete surface protected against weather or aggressive conditions Moderate: Concrete
surfaces sheltered from severe rain or freezing whilst wet concrete exposed to condensation and rain.
Concrete continuously under water. Concrete in contact or buried under non aggressive soil/ ground
water.
Severe: Concrete surface exposed to severe rain, alternate wetting and drying or occasional freezing
whilst or severe condensation

(3) Prescribed Mixes

Prescribed mixes shall have the proportion mentioned below
Classes of Type of uses Characteristic Concrete mix Mix proportion in
concrete Strength case of Prescribed
fck mix
(N/mm2)
M 10/75 Ordinary 10 Prescribed 1:3:6
M 10/40 Ordinary 10 1:3:6
M 15/20 Ordinary 15 1:2:4
M 15/40 Ordinary 15 1:2:4

Concrete mix shall be proportioned by volume. The Engineer may instruct to slight
adjustment in the proportioning to allow for variations in the specific gravity and
grading of aggregates. Such variation shall not be deemed to vary the price of the
concrete. The Engineer shall require the contractor to make trial mixes and test work
cubes to satisfy himself that the prescribed mix will give expected strengths . No
concrete shall be placed in the works until the relevant mix has been approved by the
Engineer and no variation shall be made in the mix after approval without the
Engineer’s consent, who may require further tests to be made.

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(4) Laboratory Trial Mixes

For each mix of concrete the Contractor shall prepare three number of concrete
batches with the proportion as per designed or prescribed mix as specified in the
contract. The Following test shall be carried out for each sample of each batch.
 Slump of concrete
 Compressive strength of each concrete cubes. [six test cube from each batch
prepared and 3 cube test for 7 days and 3 for 28 days]
 Density of concrete cube
Modified compositions, the quantities of other constituents being unchanged:
Water : +10% 1 batch
Water : -10% 1 batch
Cement : +15% 1 batch
Cement : -15% 1 batch
Samples shall be taken from each batch and the following action taken, all in
accordance with IS: 516.

(*) For “Smaller Contracts Works”, the following composition are suggested as a
s
t Concrete Characteristic Cement Total Fine aggr./ Water Workability
Class Strength (kg) Aggregate Total aggr. (max)
a
N/mm2 (kg) (%) (lit.)
r
M 15/40 15 250 1900 35-45 160 Stiff-Plastic
t
M 15/20
i M 20/20 20 300 1875 35-45 165-170 Stiff
n M 30/40 30 350 1825 35-45 170 Stiff
g M 30/20 30 350 1825 35-45 175 Plastic

M 35/20 35 350 1825 35-45 175 Plastic

b
a
sis for the Laboratory trials for one cu.m. of concrete.
A “result” being the average strength of the three cubes from one batch, the average
of the three results form tests at 28 days for the nominal composition shall not be
less than the Minimal Target Strength shown in Table 20.3.
One result from the modified compositions shall not be less than the nominal
strength as shown on Table 20.3.
(4) Site Trials
At least six weeks before commencing placement of concrete in the permanent
works, site trials shall be prepared for each class of concrete specified.
For each mix of concrete for which the Contractor has proposed a design and
successfully tested in Laboratory, he shall prepare three separate batches specified
hereunder using the materials which have been approved for use in the works and the
mixing plant which he propose to use for the works. The volume of each batch shall

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be the capacity of the concrete mixer proposed for full production.

Samples shall be taken from each batch and the action taken similar to the above
Sub-clause 2004 (3) (a) to (e)
The average of the three results of tests at 28 days shall not be less than the Minimal
Target Strength shown in Table 20.3.
The Contractor shall also carry out tests to determine the drying shrinkage of the
concrete unless otherwise directed by the Engineer.
Based on the results of the tests on the Laboratory trial and site trial mixes, the
Contractor shall submit full details of his proposals for mix design to the Engineer,
including the type and source of each ingredient, and the results of the tests on the
trial mixes.
If the Engineer does not agree to a proposed concrete mix for any reason, the
Contractor shall amend his proposals and carry out further trial mixes. No mix shall
be used in the works without the written consent of the Engineer.
(5) Quality control of Concrete Production
(a) Sampling
For each class of concrete in production at each plant for use in the works, samples
of concrete shall be taken at the point of mixing or of deposition as instructed by the
Engineer, all in accordance with the sampling procedures described in IS: 516 and
with the further requirements set out below.
Six 150 mm or 200 mm cubes as appropriate shall be made from each sample and
shall be cured and tested in accordance with IS: 516 three at seven days and the other
three at 28 days. Where information samples are required, such as for post tensioning
operations, three additional cubes shall be made.
The minimum frequency of sampling of concrete of each grade shall be as following:

For 1-5 m3 quantity of work at one place - 1 set of sample

3
For > 5-15 m quantity of work - 2 set. of sample
3
For > 15-30 m quantity of work - 3 set. of sample
For > 30 - 50 m3 quantity of work - 4 set. of sample
3
For more than 50 m quantity of work 4 set .of sample plus one additional for
each 50 m3 or part thereof.
At least one set of sample shall be taken from each shifts of work.
Until compliance with the Specification has been established the frequency of
sampling shall be three times that stated above and not less than 3 samples/day for
each class of concrete in production at each plant or such lower frequency as may be
instructed by the Engineer.

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(b) Testing

(i) The slump of the concrete shall be determined for each batch from which
samples are taken and in addition for other batches at the point of production
and deposition or at the frequency instructed by the Engineer.
The slump of concrete in any batch shall not differ from the value established
by the trial mixes by more than 25 mm or one third of the value whichever is
the less.
(ii) The air content of air entrained concrete in any batch shall be within 1.5 times
of the required value and the average value of four consecutive measurements
shall be within the required value expressed as a percentage of the volume of
freshly mixed concrete while tested according to IS: 1199.
(iii) Early Works: Until such times as sufficient test results are available to apply
the method of control described in (iv) below, the compressive strength of the
concrete at 28 days shall be such that no result (average of 3 cubes) is less than
the characteristic strength fck as shown in Table 20.3 under the heading “early
works test cubes” and also that the average of three consecutive results is not
less than fck +4 as shown in Table 20.3 under the same heading.
The 7-day cube result may be used as an early strength indicator, at the
discretion of the Engineer.
(iv) When at least 20 consecutive results on tested batches are available for any
class of concrete mixed in any one plant, no single result shall be less than f ck -
2
4 (N/mm ) and also the average of any group of three consecutive results shall
2
not be less than fck +4 (N/mm ).
I
n
Number of Batches Maximum coefficient of variation
Ordinary concrete High quality concrete
Aftera20 tested batches 18% 15%
Afterd50 tested batches 15% 12%
d
Standard Deviation of the results
Whereithe Coefficient of Variation =
Average Value of the results
t
ion, the Coefficient of Variation shall be less than the figure given below:
(v) Failure to comply with requirements:
If any one result in a group of three consecutive results is less than fck -4
2
(N/mm ), but the other results of group satisfy the strength requirement, then
only the batch from which the failed result was obtained shall be deemed not to
comply with the Specification.
If the average strength of the group is less than the strength requirement then

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all the batches between those represented by the first and the last result shall be
deemed not to comply with the Specification, and the Contractor shall
immediately adjust the production procedure or the mix design subject to the
agreement of the Engineer to restore compliance with the Specification. If
adjustment of the mix design is agreed, the Contractor shall again be required
to comply with Sub-clauses 2004 (3) and 2004 (4).
The Contractor shall take necessary action to remedy concrete which does not
comply with this Specification. Such action may include but not necessarily
confined to the following:
Increasing the frequency of sampling until control is again established.
Carrying out non-destructive testing such as ultrasonic measurement, load tests
or other appropriate methods.
Cutting test scores from the concrete and testing in accordance with IS: 1199.
Carrying out strengthening or other remedial work to the concrete where
possible or appropriate.
Removing the concrete.
2005 MIXING CONCRETE
(1) Proportioning
Concrete mixes shall be proportioned according to the Design mix or Prescribed mix
as specified. All mixing operations shall be supervising by experienced supervisor.
Cement and aggregate shall be batched by weight or by volume as specified in the
contract. Water may be measured by weight or volume. The quantity of cement,
eachsize of aggregate and water as indicated by the mechanism employed shall be
within a tolerance of plus or minus three percent of the respective weight/ volume
per batch agreed by the Engineer. The water to be added to the mix shall be reduced
by the amount of free water contained in the coarse and fine aggregates. This amount
shall be determined by the Contractor by a method agreed by the Engineer.
(2) Machine Mixing
Concrete for the work s shall be batched and mixed in one or more plants or concrete
mixer unless the Engineer agrees to some other arrangement. If concrete mixers are
used, there shall be sufficient number of mixtures including stand by mixers.
Batching and mixing plants shall be complying with the requirements of IS: 1791
and capable of producing a uniform distribution of the ingredients throughout the
mass. Truck mixers shall comply with the requirements of IS: 4925 and shall only be
used with the prior approval of the Engineer. If the plant proposed by the Contractor
does not fall within the scope of IS: 1791 it shall have been tested in accordance with
IS: 4634 and shall have a mixing performance within the limits of IS: 1791.
All mixing operations shall be under the control of an experienced supervisor
The aggregate storage bins shall be provided with drainage facilities arranged so that

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the drainage water is not discharged to the weigh hoppers. Each bin shall be drawn at
least once per week and any accumulations of mud or silt shall be removed
If bulk cement is used, the scale and weight hopper for cement shall be distinct from
the scale and weight hopper for aggregates.
Cement and aggregates shall be batched by weight. Water may be measured by
weight or volume.
The weighing and water dispensing mechanisms shall be maintained in good order
The nominal drum or pan capacity of the mixer shall not be exceeded. The turning
speed and the mixing time shall be as recommended by the manufacturer, but in
addition, when water is the last ingredient to be added, mixing shall continue for at
least one minute after all the water has been added to the drum or the pan.
The blades of pan mixers shall be maintained within the tolerances specified by the
manufacturer of the mixer and the blades shall be replaced when it is no longer
possible to maintain the tolerances by adjustment.
Mixers which have been out of use for more than 30 minutes shall be thoroughly
cleaned before any fresh concrete is mixed. Mixers shall be cleaned out before
changing to another type of cement.
(3) Hand Mixing
Concrete for structural purposes generally shall not be mixed by hand. However, for
small volumes of works and where non-structural concrete is required, hand mixing
may be carried out subject to approved of the Engineer.
For making hand mixing concrete, cement, sand and aggregate shall be batched
separately by volume or by weight as applicable. Then cement and sand shall be
mixed dry to uniform colour. The aggregate shall be stacked in a proper shape upon
which cement sand mix shall be spread and whole mix shall be mixed to uniform
consistency.
For hand mixed concrete the specified quantities of cement shall be increased by 10
% and not more than 0.25 cubic meter shall be mixed at one time. During windy
weather precautions shall be taken to prevent cement from being blown away in the
process of gauging and mixing.
2006 TRANSPORTATION OF CONCRETE
The concrete shall be discharged from the mixer and transported to the works by means
which shall prevent adulteration, segregation or loss of ingredients, and shall ensure that
the concrete is of the required workability at the point and time of placing. The loss of
slump between discharge from the mixer and placing shall be within the tolerances
specified in Sub-clause 2004 (5) (b) (i).
The capacity of the means of transport shall not be less than the full volume of a batch.
The time elapsing between mixing transporting placing and compacting altogether of a
batch of concrete shall not be longer than the initial setting time of the concrete. If the
placing of any batch of concrete is delayed beyond this period, the concrete shall not be

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placed in the works.

2007 PLACING OF CONCRETE
(1) Consent for Placing
Concrete shall not be placed until the Engineer’s consent has been given in writing.
The Contractor shall give the Engineer at least two full working day notice of his
intention to place concrete.
If concrete placing is not commenced within 24 hours of the Engineer’s consent the
Contractor shall again request consent as specified above.
(2) Preparation of Surface to Receive Concrete
Excavated surfaces on which concrete is to be deposited shall be prepared as set out
in Section 900.
Existing concrete surfaces shall be prepared as set out in Clause 2012. Before
deposition of further concrete, they shall be clean, hard and sound and shall be wet
but without any free standing water.
Any flow of water into an excavation shall be diverted through proper side drains to
a sump or be removed by other suitable which will prevent washing away the freshly
deposited concrete or any of its constituents. Any under drain constructed for this
purpose shall be completely grouted up when they are no longer required by a
method agreed by the Engineer.
Unless otherwise instructed by the Engineer surfaces against which concrete is to be
placed shall receive prior coating of cement slurry or mortar mixed in the
proportions similar to those of the fines proportions similar to those of the fines
portion in the concrete to be placed. The mortar shall be kept ahead of the concrete.
The mortar shall be placed into all parts of the excavated surface and shall not be less
than 5 mm thick.
If any fissures have been cleaned out they shall be filled with mortar or with concrete
as instructed by the Engineer.
The amount of mortar placed at one time shall be limited so that it does not dry out
or set before being covered with concrete.
(3) Placing Procedures
The Concrete shall be deposited as nearly as possible in its final position. It shall be
placed so as to avoid segregation of the concrete and displacement of the
reinforcement, other embedded items or form work. It shall be brought up in layers
approximately parallel to the construction joint planes and not exceeding 300 mm in
compacted thickness unless otherwise permitted or directed by the Engineer, but the
layers shall not be thinner than four times the maximum nominal size of aggregate.
When placing on a nearly horizontal surface, placing shall start at the lower end of
the surface to avoid decompaction of concrete.
Layers shall not be placed so that they form feather edges nor shall they be placed on

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a previous layer which has taken its initial set. In order to comply with this
requirement, another layer may be started before initial set of the preceding layer.
All the concrete in a single bay or pour shall be placed as a continuous operation. It
shall be carefully worked round all obstructions, irregularities in the foundations and
the like so that all parts are completely full of compacted concrete with no
segregation or honey combing. It shall also be carefully worked round and between
water stops, reinforcement, embedded steelwork and similar items which protrude
above the surface of the completed pour.
All work shall be completed on each batch of concrete before its initial set
commences and thereafter the concrete shall not be disturbed before it has set hard.
No concrete that has partially hardened during transit shall be used in the works and
the transport of concrete from the mixer to the point of placing shall be such that this
requirement can be complied with.
Concrete shall not be placed during rain which is sufficiently heavy or prolonged to
wash mortar from coarse aggregate on the exposed faces of fresh concrete. Means
shall be provided to remove any water accumulating on the surface of the placed
concrete. Concrete shall not be deposited into such accumulations of water.
In dry weather, covers shall be provided for all fresh concrete surfaces which are not
being worked on. Water shall not be added to concrete for any reason.
When concrete is discharged from the place above its final deposition, segregation
shall be prevented by the use of chutes, down pipes, trunking, baffles or other
appropriate devices.
Forms for walls shall be provided with openings or other devices that will permit the
concrete to be placed in a manner that will prevent segregation and accumulations of
hardened concrete on the formwork or reinforcement above the level of the placed
concrete.
When it is necessary to place concrete under water the Contractor shall submit to the
Engineer his proposals for the method and equipment to be employed. The concrete
shall be deposited either by bottom-discharging watertight containers or through
funnel- shaped tremies which are kept continuously full with concrete in order to
reduce to a minimum the contact of the concrete with the water. Special care shall be
taken to avoid segregation.
If the level of concrete in a tremie pipe is allowed to fall to such extent that the water
enters the pipe, the latter shall be removed from the pour and filled with concrete
before being again lowered into the placing position. During and after concreting
under water, pumping or dewatering in the immediate vicinity shall be suspended if
there is any danger that such work will disturb the freshly placed concrete.
(4) Interruptions to Placing
If the concrete placing is interrupted for any reason and the duration of the
interruption cannot be forecast or is likely to be prolonged, the Contractor shall

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immediately take the necessary action to form a construction joint so as to eliminate

as far as possible feather edges and sloping top surfaces and shall thoroughly
compact the concrete in accordance with Clause 2008. All work on the concrete shall
be completed before elapse of initial setting time and it shall not thereafter be
disturbed until it is hard enough to resist damage. Plant and materials to comply with
this requirement shall be readily available at all time during concrete placing.
Before concreting is resumed after such an interruption the Contractor shall cut out
and remedy all damaged or uncompacted concrete, feather edges or any undesirable
features and shall leave a clean sound surface against which the fresh concrete may
be placed.
If it becomes possible to resume concrete placing without contravening the
Specification and the Engineer consents to a resumption, the new concrete shall be
thoroughly worked in and compacted against the existing concrete so as to eliminate
any cold joints.
In case of long interruption concrete shall be resumed as directed by Engineer.
(5) Dimension of Pours
Unless otherwise agreed by the Engineer, pours shall not be more than two meters
high and shall as far as possible have a uniform thickness over the plan area of the
pour. Concrete shall be placed to the full planned height of all pours except in the
circumstances described in Sub-clause 2007 (4).
The Contractor shall plan the dimensions and sequence of pours in such a way that
cracking of the concrete does not take place due to thermal or shrinkage stresses.
(6) Placing Sequence
The Contractor shall arrange that the intervals between successive lifts of concrete in
one section of the works are of equal duration. This duration shall not be less than
three days or not more than seven days under temperate weather conditions unless
otherwise agreed by the Engineer.
Where required by the Engineer to limit the opening of construction joints due to
shrinkage, concrete shall not be placed against adjacent concrete which is less than
21 days old.
Contraction gaps in concrete shall be of the widths and in the locations as shown on
the Drawing and they shall not be filled until the full time interval shown on the
Drawing has elapsed.
2008 COMPACTION OF CONCRETE
Concrete shall be fully compacted throughout the full extent of the placed layer. It shall
thoroughly worked against the formwork and around any reinforcement and other
embedded item, without displacing them. Care shall be taken at arises or other confined
spaces. Successive layers of the same pour shall be thoroughly worked together.
Concrete shall be compacted with the assistance of mechanical of immersion vibrators,
unless the Engineer agrees another method.

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Immersion and surface vibrators shall operate at a frequency of between 70 and 200
hertz. The Contractor shall ensure that vibrators are operated at pressures and voltages
not less than those recommended by the manufacturer in order that the compactive effort
is not reduced.
A sufficient number of vibrators shall be operated to enable the entire quantity of
concrete being placed to be vibrated for the necessary period and, in addition, stand-by
vibrators shall be available for instant use at each place where concrete is being placed.
Vibration shall be continued at each until the concrete ceases to contract, air bubbles have
ceased to appear, and a thin layer of mortar has appeared on the surface. Vibrators shall
not be used to move concrete laterally and shall be withdrawn slowly to prevent the
formation of voids.
The vibrators shall be inserted vertically into the concrete to penetrate the layer
underneath at regular spacing which shall not exceed the distance from the vibrator over
which vibration is visibly effective and some extent of vibration is overlapped.
Vibration shall not be applied by way of reinforcement nor shall the vibrator be allowed
to touch reinforcement, sheathing ducts or other embedded items.
2009 CURING OF CONCRETE
(1) General
Concrete shall be protected during the first stage of hardening from loss of moisture
and from the development of temperatures differentials within the concrete sufficient
to cause cracking. Concrete shall be cured with wet cotton mat, sheet material or
other compound for curing approved by the Engineer. The methods used for curing
shall not cause damage of any kind to the concrete.
Curing shall be continued for as long as may be necessary to achieve the above
objectives but not less than seven days or until the concrete is covered by successive
construction whichever is the shorter period.
The above objectives shall be dealt with in Sub-clauses 2009 (2) and 2009
(3) but nothing shall prevent both objectives being achieved by a single method
where circumstances permit.
The curing process shall commence as soon as the concrete is hard enough to resist
damage from the process. In the case of large areas or continuous pours, it shall
commence on the completed section of the pour before the rest of the pour is
finished.
(2) Loss of Moisture
Exposed concrete surfaces shall be closely covered with impermeable sheeting,
properly secured to prevent its removal by wind and the development of air spaces
beneath it. Joints in the sheeting shall be lapped by at least 300 mm.
If it is not possible to use impermeable sheeting, the Contractor shall keep the
exposed surfaces continuously wet by means of water spray or by covering with a

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water absorbent material which shall be kept wet, unless this method conflicts with
Sub-clause 2009 (3).
Water used for curing shall be of the same quality as that used for mixing.
Formed surfaces may be cured by retaining the formwork in place for the required
curing period.
Alternatively, Approved curing compound shall be used to cover exposed surface.
If instructed by the Engineer, the Contractor shall, in addition to the curing
provisions set out above provide a suitable form of shading to prevent the direct rays
of the sun reaching the concrete surfaces for at least the first four days of the curing
period.
(3) Limitation of Temperature Differentials
The Contractor shall limit the development of temperature differentials in concrete
after placing by any means appropriate to the circumstances including the following:
(a) limiting concrete temperatures at placing as set out in Sub-clause 2011 (2);
(b) use of low heat cement for mass concreting, subject to the agreement of the
Engineer;
(c) leaving formwork in place during the curing period. Steel forms shall be
suitably insulated on the outside;
(d) preventing rapid dissipation of heat from surfaces by shielding from wind.
2010 PROTECTION OF FRESH CONCRETE
Freshly placed concrete shall be protected from rainfall and from water running over the
surface until it is sufficiently hard to resist damage from these causes.
Concrete placed in the works shall not be subjected to any loading including traffic until it
has attained at least its characteristic strength as defined in Clause 2004.
2011 CONCRETING IN HOT WEATHER
(1) General
The Contractor shall prevent damage to concrete arising from exposure to extreme
temperatures, and shall maintain in good working order all plant and equipment
required for this purpose
In the event that conditions become such that even with the use of equipment the
requirements cannot be met, concrete placing shall immediately cease until such time
as the requirements can again be met.
(2) Concrete Placing in Hot Weather
During hot weather the Contractor shall take all measures necessary to ensure that
o
the temperature of concrete at the time of placing in the works does not exceed 30 C
and that the concrete does not lose any moisture during transporting and placing.
Such measures may include but are not necessarily limited to the following:
(a) Shielding aggregates from direct sunshine.

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

(b) Use of a mist water spray on aggregates.

(c) Sun shields on mixing plants and transporting equipment.
Surfaces in which concrete is to be placed shall be shielded from direct sunshine and
surfaces shall be thoroughly wetted to reduce absorption of water from the concrete
placed on or against them.
After concrete has been placed, the selected curing process shall be commenced as
soon as possible. If any interval occurs between completion of placing and start of
curing, the concrete shall be closely covered during the interval with polythene sheet
to prevent loss of moisture.
2012 CONSTRUCTION JOINTS
Whenever concrete is to be bonded to other concrete which has hardened, the surface of
contact between the sections shall be deemed a construction joint.
Where construction joints are shown in the Drawing, the Contractor shall form such joints
in such positions. The locations of joints, which the Contractor requires to make for the
purpose of construction, shall be subject to the approval of the Engineer. Construction
joints shall be in vertical or horizontal planes except in sloping slabs where they shall be
normal to the exposed surface or elsewhere where the Drawing require a different
arrangement.
Construction joints shall be arranged as to reduce to a minimum the effects of shrinkage
in the concrete after placing, and shall be placed in the most advantageous positions with
regard to stresses in the structures and the desirability of staggering joints.
Feather edges of concrete at joints shall be avoided. Any feather edges which may have
formed where reinforcing bars project through a joint shall be cut back until sound
concrete has been reached.
The intersections of horizontal and near horizontal joints and exposed faces of concrete
shall appear as straight lines produced by use of a guide strip fixed to the formwork at the
top of the concrete lift, or by other means acceptable to the Engineer.
Construction joints formed as free surfaces shall not exceed a slope of 20 per cent from
the horizontal.
The surface of the fresh concrete in horizontal or near horizontal joints shall be
thoroughly cleaned and roughened by means of high pressure water, and air jets or wire
brush, when the concrete is hard enough to withstand the treatment without the leaching
of cement. The surface of vertical or near vertical joints shall be similarly treated if
circumstances permit the removal of formwork at a suitable time.
Where concrete has become too hard for the above treatment to be successful, the surface
whether formed or free shall be thoroughly scabbled by mechanical means, manually or
wet sand blasted and then washed with clean water. The indentations produced by
scabbling shall not be less than 10 mm deep and shall be away from the finished face by
40 mm.

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If instructed by the Engineer the surface of the concrete shall be thoroughly brushed with
a thin layer of mortar composed of one part of cement to two parts of sand by weight and
complying with Sub-clause 2502 (2) immediately prior to the deposition of fresh
concrete. The mortar shall be kept just ahead of the fresh concrete being placed and the
fresh layer of concrete shall be thoroughly and systematically vibrated to full depth to
ensure complete bond with the adjacent layer.
No mortar or concrete shall be placed until the joint has been inspected and approved by
the Engineer.
2013 RECORDS OF CONCRETE PLACING
Records of the details of every pour of concrete placed in the works shall be kept by the
Contractor in a form agreed by the Engineer. These records shall include class of concrete,
location of pour, date and duration of pour, ambient temperature and concrete temperature
at time of placing and all relevant meteorological information such as rain, wind etc.,
moisture contents of the aggregates, details of mixes batch numbers, cement batch
number, results of all tests undertaken, part of the structure and place where test cube
samples are taken from.
The Contractor shall supply to the Engineer four copies of these records each week
covering work carried out the preceding week. In addition, he shall supply to the Engineer
monthly histograms of all 28 day cubes strength results together with cumulative and
monthly standard deviations, Coefficient of Variation, and any other information which
the Engineer may require concerning the concrete placed in the works.
2014 REINFORCEMENT
(1) General
Reinforcement as plain bars ad deformed bars and steel fabric shall comply with the
following Standards.
NS: 191/ IS: 1786 for high strength deformed steel bars and wires.
IS: 1566 for steel mesh fabric.
NS: 84/ IS: 432 mild steel and medium tensile steel bars.
All reinforcement shall be from an approved manufacturer and, if required by the
Engineer, the Contractor shall submit the ISI certification mark or other test
certificate from the manufacturer acceptable to the Engineer.
The sampling and frequency of testing shall be as set out in the NS: 84 and NS: 191.
All reinforcement not complying with the Specification shall be removed from site.
(2) Storage of Reinforcement
All reinforcement shall be delivered to site either in straight lengths or cut and bent.
No reinforcement shall be accepted in long lengths which have been transported bent
over double.
Any reinforcement which is likely to remain in storage for a long period shall be
protected from the weather so as to avoid corrosion and pitting. All reinforcement

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which has become corroded or pitted to an extent which, in the opinion of the
Engineer, will affect its properties shall either be removed from site or may be tested
for compliance with the appropriate Indian Standard in accordance with Sub-clause
2014 (1) at the Contractor expense.
Reinforcement shall be stored at least 150 mm above the ground on clean area free
of mud and dirt and sorted out according to category, quality and diameter.
(3) Bending Reinforcement
Unless otherwise shown on the Drawing, bending and cutting shall comply with IS:
2052.
The Contractor shall satisfy himself as to the accuracy of any bar bending schedules
supplied and shall be responsible for cutting, bending, and fixing the reinforcement
in accordance with the Drawing.
Bars shall be bent mechanically using appropriate bar benders. Bars shall be bent
o
cold by the application of slow steady pressure. At temperature below 5 C the rate of
bending shall be reduced if necessary to prevent facture in the steel. Bending
reinforcement inside the forms shall not be permitted except for mild steel bars of
diameter less or equal to 12 mm, when it is absolutely necessary.
After bending, bars shall be securely tied together in boundless or groups and legibly
labelled as set out in IS: 2502.
(4) Fixing Reinforcement
Reinforcement shall be thoroughly cleaned. All dirt, scale, loose rust, oil and other
contaminants shall be removed before placing it in position. If the reinforcement is
contaminated with concrete form previous operation, it shall be cleaned before
concreting in that section.
Reinforcement shall be securely placed and fixed in position as shown in the
drawing or directed by the Engineer.
Unless otherwise agreed by the Engineer, all intersecting bars shall be either tied
together with not less than 1.6 mm diameter soft annealed iron wire and the end of
the wire turned into the body of the concrete, or shall be secured with a wire clip of
a type agreed by the Engineer.
Spacer blocks shall be used for ensuring that the correct cover is maintained on the
reinforcement. Blocks shall be as small as practicable and of a shape agreed by the
Engineer. They shall be made of mortar mixed in the proportions of one part of
cement to two parts of sand by weight. Wires cast into the block for tying in to the
reinforcement shall have not less than 1.6 mm diameter and shall be soft annealed
iron.
Alternatively, another type of spacer block may be used subjected to the Engineer’s
approval.
All reinforcement shall be checked of shape, size, diameter and number where

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

necessary. Reinforcement shall be rigidly fixed so that it remain intact during placing
of concrete. Any fixers made to the formwork shall not remain within the space to be
occupied by the concrete being placed.
No splices shall be made in the reinforcement except where shown on the Drawing
or agreed by the Engineer. Splice lengths shall be as shown on the Drawing or
directed by the Engineer.
Reinforcement shall not be welded except where required by the contract or agreed
by the Engineer. If welding is employed, all welded splices shall be full penetration
butt welds complying with the procedures set out in IS: 2751 or IS: 9417 as
applicable. Mechanical splices shall not be used unless the Engineer agrees
otherwise. Acceptance for welded or mechanical splices of approved design shall be
based on qualification tests to be carried out by the Contractor prior to start of the
work. Construction control testing as instructed by the Engineer shall be also carried
out.
The Contractor shall ensure that reinforcement left exposed in the works shall not
suffer distortion, displacement or other damage. When it is necessary to bend
protruding reinforcement aside temporarily, the radius of the bend shall not be less
than four times the bar diameter for mild steel bars of six times the bar diameter for
high yield bars. Such bends shall be carefully straightened without leaving residual
kinks or damaging the concrete round them before concrete placing. In no
circumstances heating and bending of high yield bars shall be permitted.
Bars complying with IS: 1786 or other high tensile bars shall not be bent after
placing in the works.
2015 CONCRETE FOR SECONDARY PURPOSES
(1) Non-structural Concrete
Non-structural concrete (NS concrete) shall be used only for non-structural purposes
where shown on the Drawing.
NS concrete shall be compound of ordinary Portland cement and aggregate
complying with this Specification.
The weight of cement mixed with 0.3 cubic metres of combined aggregate shall not
be less than 50 kg. The mix shall be proportioned by weight or by volume. The
maximum aggregate size shall be 40 mm nominal.
The concrete shall be mixed by machine or by hand in accordance with Sub-clause
2015 (3) to a uniform colour and consistency before placing. The quantity of water
used shall not exceed that required to produce a concrete with sufficient workability
to be placed and compacted where required.
The concrete shall be compacted by hand towels or rammers or by mechanical
vibration.
(2) No Fines Concrete

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No fines concrete (NF concrete) is intended for use where a porous concrete is
required and shall only be used where shown on the Drawing or instructed by the
Engineer.
The mix shall consist of Ordinary Portland cement and aggregate complying with
this Specification. The aggregate size shall be 40 mm to 10 mm only. The weight of
cement mixed with 0.3 cubic metres of aggregate shall not be less than 50 kg. The
quantity of water shall not exceed that required to produce a smooth cement paste
which will coat evenly the whole of the aggregate.
(3) Hand Mixed Concrete
Concrete for structural purposes shall not be mixed by hand. Where non-structural
concrete is required, hand mixing may be carried out subject to approval of the
Engineer.
For making hand mixed concrete, cement sand and aggregate shall be batched
separately by volume or by weight as applicable. Then cement and sand shall be
mixed dry to uniform colour. The aggregate shall be stacked in a proper shape upon
which cement sand mix shall be spread and whole mix shall be turned up and down
to have uniform mix of all ingredients. Then water shall be added as specified in
Sub-clause 2015 (1) and shall be mixed to uniform consistency.
For hand mixed concrete the specified quantities of cement shall be increased by
10% and not more than 0.25 cubic meter shall be mixed at one time. During windy
weather precautions shall be taken to prevent cement from being blown away in the
process of gauging and mixing.
2016 EARLY LOADING
No load shall be applied to any part of a structure until the specified curing period has
expired, and thereafter loading shall be allowed after approval by the Engineer. The
Engineer’s decision shall be based on the type of load to be applied, the age of concrete,
the magnitude of stress induced and the propping of the structure.
No structure shall be opened to traffic until test cubes have attained the specified
minimum 28 days’ strength as defined in Clause 2004.

2017 TEST AND STANDARD OF ACCEPTANCE

(1) General:
Concrete shall conform to the surface finish and tolerance as prescribed in these
specifications for respective components.
Random sampling and lot by lot of acceptance inspection shall be made for the 28
days’ cube strength of concrete.
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;

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

i. No individual lot shall 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/ structure
(2). Sampling and testing
Concrete for making 3 test cubes shall be taken from a batch of concrete at point of
delivery into construction, according to procedure laid down in IS: 1199.
A random sampling procedure to ensure that each of the concrete batches forming
the lot under acceptance inspection has equal chance of being chosen for taking
cubes150 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. Test at other age also 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
initial setting time or where any ingredients are added subsequent to mixing, separate
set 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.
(3) Test specimen and sample strength:
Three test specimens shall be made from each sample for testing at 28 days.
Additional cubes maybe 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 that ± 15 per cent of the average. If
variation is more, the test results of the sample are invalid.
The minimum frequency of sampling of concrete of each grade shall be in
accordance with Table 5.2.
(4) Acceptance criteria
(a) Compressive Strength
I Cubes
The concrete shall be taken as having the specified compressive strength when
both the following conditions are met:
i. The mean strength determined from any group of four consecutive non
overlapping samples exceeds the specified characteristic compressive
strength by 3 MPa.
ii. Strength of any sample is not less than the specified characteristic
compressive strength minus 3 MPa.

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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
II Cores
When the concrete does not satisfy both the condition given in I 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 result 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 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.
(b) Chloride and Sulphate Content
Where Choloride and Sulphate is specified ,The total chloride and sulphuric
anhydride (SO3) content of all the constituents of concrete as a percentage of mass of
cement in the mix shall not exceed the values given in this Section of the
specifications.
(c) 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 per cent of the specified
value.
(d) 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 per cent of the specified
value.
(e) Permeability Test
Where Permeability of concrete is specified, 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 be
prepared

SECTION 2000 CONCRETE FOR STRUCTURES Page 20-26

 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

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 the
specimen can be subjected to a water pressure upto7 bars.
iii. The concrete specimen shall be subjected to a water pressure of 0.5
N/mm2 from the top for the 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 fail.
iv. After 3 days, the pressure shall be released and the sample shall be taken
out. The specimen shall be split in the middle 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
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. Any additional
work required by the Engineer for such acceptance shall be carried out by
the Contractor at his cost. In such case payment for such work shall be
made at reduced rate proportional to reduced strength rate. In case the
concrete is not found to be acceptable even after investigation, the
Contractor shall remove the rejected concrete forthwith.
2018 MEASUREMENT
(1) Concrete
Concrete laid in place as specified in the Drawing or directed by the Engineer shall
be measured in cubic metre separately for each class. No deduction shall be made in
the measurement for:
(a) bolt holes, pockets, box outs an cast in components provided that the volume of
each is less than 0.15 cubic metres;
(b) mortar beds, fillets, drips, rebates, recesses, grooves, chamfers and the like of
100 mm total width or less;
(c) reinforcement
(2) Blinding Concrete/Non Structural Concrete
Blinding concrete laid in place shall be measured in cubic metre. No deduction shall
be made for openings provided that the area of each is less than 0.5 square metres.
Blinding concrete over hard material shall be measured as the volume used provided
that the maximum thickness of 150 mm allowed for over break in not exceeded.
(3) Admixtures, Workability and Hardening Agents and Curing Compounds
Unless stated otherwise, rate of concrete shall deemed to include admixture,
workability, hardening agent and curing compounds.

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

(4) Reinforcement
All types of reinforcement shall be measured in length including hooks, if any,
separately for different diameters as actually used in works or as directed by the
Engineer, excluding overlaps. From the length so measured, the weight of
reinforcement shall be calculated in ton on the basis of IS: 1732.
Wastage, overlaps, couplings, welded joints, spacer bars, chairs, stays, hangers and
annealed steel wire or other method for binding and placing shall not be measured
and cost of these items shall be deemed to be included in the rates for reinforcement.
An average weight of at least 5 samples each one metre length shall be determined
by the laboratory approved by the Engineer. The weight of each type of the
reinforcement shall be determined by multiplying average weight of the respective
reinforcement by its length.
(5) Fabric Reinforcement
Fabric reinforcement laid as per Drawing or as directed by the Engineer shall be
measured in square meter. No allowance shall be made for laps and wastage.

2019 PAYMENT
(1) Concrete
Every class of concrete shall be paid as per respective contract unit rate. In addition
to those specified in Clause 112 the respective rate shall also include the cost of:
(a) All materials including admixture and workability agent, curing agent, labour,
Tools, Plants and equipment required for mixing, transporting and placing in
position, vibrating and compacting, finishing and curing including all
incidental expenses.
(b) Unless mentioned separately as an item in contract sampling and testing,
quality assurance and supervision
(c) Unless mentioned separately as an item in contract, cost of providing, fixing,
and removing formwork, Staging required for concrete work as per Section
1800 of these specification.
(d) Placing and compacting against excavated surfaces where required including
any additional concrete to fill over break and working space.
(e) Complying with the requirements of Clauses 2001 to 2013, 1806 and 1807.
(2) Reinforcement
The reinforcement shall be paid at contract unit rate. In addition to those specified in
Clause 112 the rate shall also include compensation for the cost of providing, cutting
to length, splice lengths additional to those shown on the Drawing, laps, bending,
hooking, waste incurred by cutting, cleaning, spacer blocks, provision and fixing of
chairs or other types of support, welding, fixing the reinforcement in position
including the provision of wire or other material for supporting and tying the
reinforcement in place, bending reinforcement aside temporarily, and straightening,

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

place and compacting concrete around reinforcement and for complying with Clause
2014.
(3) Fabric Reinforcement
The fabric reinforcement shall be paid at contract unit rate which shall be also
inclusive of compensation for wastage and laps.

SECTION 2000 CONCRETE FOR STRUCTURES Page 20-29

 SECTION 2100: PRE-STRESSING
PAGE NO

2101 SCOPE 1

2102 GENERAL 1

2103 MATERIALS 1

2104 TESTING OF PRE-STRESSING STEEL AND ANCHORAGES 4

2105 WORKING PROCEDURE 4

2106 SUPERVISION 7

2107 TENSIONING EQUIPMENT 7

2108 POST-TENSIONING 8

2109 GROUTING OF PRE- STRESSED TENDONS 9

2110 PRE-TENSIONING 17

2111 PROTECTION OF ENDS 20

2112 SAFETY PRECAUTIONS DURING TENSIONING 21

2113 SURFACE PREPARATION 21

2114 TRANSPORTATION STORAGE AND HANDLING OF PRECAST GIRDERS

21

2115 TOLERANCES 22

2116 TESTS AND STANDARDS OF ACCEPTANCE 22

2117 MEASUREMENT 22

2118 PAYMENT 23
 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

SECTION 2100 – PRE-STRESSING

2101 SCOPE
The work shall consist of imparting pre-stress to structural concrete members by stressing
of wires/ strands/ tendons/ cables with jack of required capacity and holding them between
appropriately designed anchorages fixed internally or externally to the members.
This Section covers the materials, equipment and methods required for carrying out pre-
stressing operations on in-situ concrete. This Section also covers the classes of concrete
appropriate to pre-stressed concrete. The production of in-situ concrete is covered by
Section 2000.
2102 GENERAL
The work shall be carried out in accordance with the drawings and these Specifications or
as approved by the Engineer.
Structural Concrete and un-tensioned steel for the production of pre-stressed concrete
members shall conform to the requirements of Section 2000 of these Specifications,
unless specifically modified by requirements set forth in this Section.
The Contractor shall submit to the Engineer full details of the plant he proposes to use for
the installation of pre-stressing tendons, the materials he proposes to use and the
arrangements he proposes to make. He shall also submit evidence of his competence to
undertake the installation.
All pre-stressing components, sheathing ducts, anchorages, pre-stressing tendons, jack,
etc. shall be stored in clean dry conditions. They shall be clean and free from rust at the
time of fixing in position and subsequent concreting.
2103 MATERIALS
All materials shall conform to Section 600 of these Specifications.
(1) Cement and Concrete classes for Pre-stressed Concrete Structures
Cement for pre-stressed concrete shall be exclusively Ordinary Portland Cement
(OPC) or High Strength Portland Cement (HSPC) complying with Clause 614.
Concrete classes for pre-stressed concrete comply with Section 2000.
(2) Sheathing
(a) General
The sheathing ducts shall be of the spiral corrugated type either in mild steel or
HDPE or in PP for internal tendons. They shall be in as long lengths as practicable
from considerations of handling and transportation without getting damaged.
External tendons shall be housed in either High Density Poly Ethylene (HDPE)
sheaths or metallic steel sheaths (plain or with protective coatings). Which have
smooth internal surfaces.

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

(b) M.S. Sheathing Ducts

Unless otherwise specified, the material shall be Cold Rolled Cold Annealed
(CRCA) Mild Steel conforming to IS: 513 intended for mechanical treatment and
surface refining but not for quench hardening or tempering.
The material shall be clean free from rust and normally be bright finished. However,
where specified, as in case of use in aggressive environment, galvanized or lead-
coated mild steel strips shall be used.
The sheathing shall confirm to the requirements specified in Table 21.1 and test on
Sheathing duct shall be carried out in accordance with IS 1343:2012

Table 21.1: Details of Ducts

No. of Diameter of Duct in Thickness of MS Thickness of
Strands/ mm Sheathing in mm HDPE duct in
Dia. in mm Metallic HDPE mm

6/13 50 50 0.3 2.0

122/13 75 75 0.4 2.5
19/13 85 85 0.4 2.5
27/13 100 100 0.5 3.0
12/15 85 85 0.4 2.5
19/15 100 100 0.5 3.0
27/15 125 130 0.5 4.0
(c) Corrugated HDPE Sheathing Ducts
The material for the ducts shall be high density polyethylene or propylene with more
than 2 percent carbon black to provide resistance to ultraviolet degradation. The
ducts shall be corrugated on both sides. All tests on raw materials and tests to be
conducted on the finished product, shall be in accordance with fib (international
federation for structural concrete) Technical Report Bulletin 7 “Corrugated Plastic
ducts for internal bonded post tensioning”
Each batch of the HDPE ducts supplied to the site shall be accompanied by the
supplier’s certificate for properties of the raw materials which shall comply with the
Technical report Bulletin 7. In addition the shore hardness for D-3 sec value shall be
60 ±5. For the approval of the finished product, the tests mentioned in the Appendix
A1 to A 9 of the fib Technical Report Bulletin7, shall be conducted at the reputed
institutions or at the manufacturer’s laboratories. Result shall comply with the
provisions of the fib Technical report Bulletin 7, except for the water resistance,
minimum bending radius and bond length test which are modified as follows:
i. Water Resistance Test: The wear resistance of the duct i.e. the minimum
residual wall thickness after loss, shall not be less than 1.5 mm for ducts up to
85 mm in diameter and not less than 2 mm for ducts greater than 85 mm in
diameter.

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

ii. Minimum bending resistance: The test apparatus shall be identical to the wear
test apparatus with the same clamping force. However samples shall not be
moved but shall be as held in position for a period of 7 days. The residual wall
thickness shall be as mentioned in above i.

iii. Bond length test: The ducts shall transmit full tendon strength from the tendon
to the surrounding concrete over a length of not greater than 40 times duct
diameter.
Each supply of the ducts shall be accompanied by test report of the finished product
also. The test certificates issued by the institutes will be valid for a period of two
years.
(d) Diameter and thickness of Sheathing Ducts
The internal diameter and thickness of sheathing shall be as shown in the drawing or
as indicated in Table 21.1, whichever is greater.
Where pre-stressing tendons are required to be threaded after concreting, the internal
diameter of sheathing shall be about 5 mm larger than required above for spans more
than 30 m. In severe environment, cables shall be threaded after concreting. In such
cases a temporary tendon shall be inserted in the sheathing or the sheathing shall be
stiffened by the suitable method during concreting.
(3) Anchorages
Pre-stressing accessories like jacks, anchorages, wedges, block plates, etc. shall be
procured from authorised manufacturers only. Anchorages shall conform to
“Recommendations for acceptance and application of pre-stressing systems”
published by FIB. The pre-stressing accessories shall be subjected to an acceptance
test prior to their actual use on the work. Test certificates from a laboratory fully
equipped to carry out the tests shall be furnished to the Engineer. Such test
certificates shall not be more than 12 months old at the time of making the proposal
for adoption of a particular system for the project.
No damaged anchorages shall be used. Steel parts shall be protected from corrosion
at all times. Threaded parts shall be protected by greased wrappings and tapped holes
shall be protected by suitable plugs until used. The anchorage components shall be
kept free from mortar and loose rust and any other deleterious coating.
Swages of pre-stressing stand and button-heads of pre-stressing wire, where
provided shall develop a strength of at least 95 per cent of the specified breaking
load of the strand or wire as the case may be. Where swaging/button-heading is
envisaged, the Contractor shall furnish details of his methodology and obtain
approval of the Engineer, prior to his taking up the work.
Un- tensioned Steel reinforcements, around anchorages shall conform to the details
of pre-stressing system and as shown on the drawing.
(4) Couplers

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

Couplers or other similar fixtures used in conjunction with the pre-stressing strands
or bars shall have an ultimate tensile strength of not less than the strength of the
individual strands or bars being joined and shall also meet the requirements of
individual anchorages
2104 TESTING OF PRE-STRESSING STEEL AND ANCHORAGES
All materials specified for testing shall be furnished free of cost and shall be delivered in
time for tests to be made well in advance of anticipated time of use.
All wire, stand or bars to be shipped to the site shall be assigned a lot number and tagged
for identification purposes. Anchorage assemblies to be shipped shall be like-wise
identified.
All samples submitted shall be representative of the lot to be furnished and in the case of
wire or strand, shall be taken from the same master roll. The Contractor shall furnish
samples of at least 5.0 m length selected from each lot for testing. Also, two anchorage
assemblies, complete with distribution plates of each size or types to be used, shall be
furnished along with short lengths of strands as required.
2105 WORKING PROCEDURE
(1) Cleaning:
Tendons shall be free from loose rust, oil, grease, tar, paint, mud or any other
deleterious substance.
Cleaning of the steel may be carried out by immersion in suitable solvent solutions,
wire brushing or passing through a pressure box containing carborundum powder.
However, the tendons shall not be brought to a polished condition.
(2) Straightening
High tensile steel wire and strand shall be supplied in coils of sufficiently large
diameter such that tendons shall retain their physical properties and shall be straight
as it unwinds from the coil. Tendons of any type that are damaged, kinked or bent
shall not be used.
The packing of pre-stressing wire/strand shall be removed only just prior to making
of cable for placement. Suitable stands be provided to facilitate uncoiling of
wires/strands without damage to steel. Care shall be taken to avoid the possibility of
steel coming into contact with the ground.
(3) Positioning
(a) Post-Tensioning
Pre-stressing tendons shall be accurately located and maintained in position, both
vertically and horizontally, as per drawings.
Tendons shall be so arranged that they have a smooth profile without sudden bends
or kinks.
The location of pre-stressed cables shall be such as to facilitate easy placement and

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

vibration of concrete in between the tendons. High capacity tendon shall be used to
reduce the number of cables thereby eliminating the necessity of grouping. The
selected profiles of the tendons shall be such that their anchorages are not located in
the top deck surface. Where two or more rows of cables have to be used, the cables
shall be vertically in line to enable easy flow of concrete. The clear vertical and
horizontal distances between any two cables shall in no case be less than 100 mm
anywhere along the length of the superstructure. Where precast segments are used,
the clear distance shall be at least 150 mm.
Sheathing shall be placed in correct position and profile by providing suitable
ladders and spacers. Such ladders may be provided at intervals of approximately 1.0
m. Sheathing shall be tied rigidly with such ladders/spacer bars so that they do not
get disturbed during concreting.
The method of supporting and fixing shall be such that profile of cables is not
disturbed during vibrations, by pressure of wet concrete, by workmen or by
construction traffic.
Sheathing in which the permanent tendon will not be in place during concreting shall
have a temporary tendon inserted or shall be stiffened by some other method to the
approval of the Engineer. The temporary tendon shall be pulled out before threading
the permanent tendon into place by a special threading machine or other contrivance.
Where possible tendons shall not be placed until immediately prior to stressing.
Tendons shall be handled with care to avoid damage or contamination, to either the
tendon or the sheathing. Any tendons damaged or contaminated shall be cleaned or
replaced.
(b) Pre-Tensioning
Pre-stressing steel shall be accurately located and maintained in position, both
vertically and horizontally, as per drawings.
Each anchorage device shall be set square to the line of action of the corresponding
pre-stressing tendon and shall be positioned securely to prevent movement during
concreting.
The anchorage devices shall be cleaned to the satisfaction of the Engineer prior to
the placing of concrete. After concreting, any mortar or concrete which adheres to
bearing or wedging surfaces, shall be removed immediately.
(4) Cutting
Cutting and trimming of wires or strands shall be done by suitable mechanical or
flame cutters. When a flame cutter is used, care shall be taken to ensure that the
flame does not come in contact with other stressed steel. The location of flame
cutting of wire or strand shall be kept beyond 75 mm of where the tendon will be
gripped by the anchorage or jacks.
In post-tensioning the ends of pre-stressing steel projecting beyond the anchorages,
shall be cut after the grout has set.

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

(5) Protection of Pre-stressing Steel

Pre-stressing steel shall be continuously protected against corrosion, until grouted.
The corrosion protector shall have no deleterious effect on the steel or concrete or on
the bond strength of steel to concrete. Grouting shall conform to these specifications
or as directed by the Engineer.
In the case of external pre-stressing, steel shall be encased in suitable polyethylene
pipes before grouting.
(6) Sheathing Duct Joints
(a) General
The sheathing and all joints shall be water-tight and shall withstand a pressure of 1.1
times the grouting pressure and maximum grouting head due to grout. Any
temporary opening in the sheathing shall be satisfactorily plugged and all joints
between sheathing and any other part of the pre-stressing system, shall be effectively
sealed to prevent entry of mortar, dust, water, or other deleterious matter. Sheathing
shall be neatly fitted at joints without internal projection or reduction of diameter.
Enlarged portions of the sheathing at coupling or anchorages shall be of sufficient
length to provide for the extension of the tendons.
Special attention shall be paid to the junction at the anchorage end, where the
sheathing must tightly fit on the protruding trumpet end of anchorage and thereafter
sealed preferably with heat shrink tape, to make it water-proof.
(b) Coupling of MS Sheathing Ducts
For major projects, the sheathing duct should preferably be manufactured at the
project site utilizing appropriate machines. With such an arrangement, long lengths
of sheathing ducts may be used with consequent reduction in the number of joints
and couplers.
Where sheathing duct joints are unavoidable, they shall be made cement slurry tight
by the use of corrugated threaded sleeve couplers, which can be tightly scree
The length of the coupler should not be less than 150 mm but should be increased up
to 200 mm wherever practicable. The joints between the end of coupler and duct
shall be sealed with tape to prevent penetration of slurry during concreting. The
couplers of adjacent ducts shall be staggered wherever practicable. As far as
possible, couplers should not be located in curved zones. The corrugated sleeve
couplers can be conveniently manufactured using the sheath making machine with
next higher size of die set.
(c) Coupling of HDPE Sheathing Ducts
The HDPE sheathing can be joined by any one of the following methods;
 Use of threaded sleeve couplers in the same manner as given for metallic

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

sheathing
 Welding of two ends of HDPE sheathing using appropriate machine such as
Roaster Machine or Mirror Machine
 Use of heat shrink couplers made of HDPE sleeves. The sleeves are
integrated with parent sheathing by hot process by using heating torch.
(7) Grout vents
Grout vents of at least 20 mm diameter shall be provided at both ends of the
sheathing and at all valleys and crests along its length. For cables longer than 50 m
grout vents or drains may be provided at or near the lowest points. Additional vents
shall also be provided along the length of sheathing such that the spacing of
consecutive vents do not exceed 20 m. Each of the grout shall be provided with a
plug or similar device capable of withstanding a pressure of 1.0 MPa without the
loss of water, air pressure or grout.
(8) Anchorages
All bearing surfaces of the anchorages shall be cleaned prior to concreting and
tensioning.
Anchor cones, blocks and plates shall be securely positioned and maintained during
concreting such that the centre line of the duct passes axially through the anchorage
assembly.
The anchorages shall be recessed from the concrete surface by a minimum cover of
100 mm.
After the pre-stressing operations are completed and pre-stressing wires/strands are
cut, the surface shall be painted with two coats of epoxy of suitable formulation
having a dry film thickness of 80 microns per coat and entire recess shall be filled
with concrete or non-shrink/pre-packaged mortar or epoxy concrete.
2106 SUPERVISION
Pre-stressing operation and grouting shall be entrusted only to specially trained and
qualified personnel. All pre-stressing accessories shall be procured from authorized
manufacturers with in-house testing facilities. The Contractor shall be required to engage
specialized agencies who should also be entrusted with the total service contract for
fabrication of cables, protection of cables during concreting, pre-stressing and grouting.
Necessary certificates shall be accorded by such specialized agencies that the work has
been carried out in accordance with prescribed specifications. In exceptional cases, the
pre-stressing and grouting operations could be entrusted to the bridge Contractor himself,
if the Employer is convinced that he is well experienced and has qualified personnel and
sufficient track record to substantiate his performance in the particular system of pre-
stressing being adopted.
2107 TENSIONING EQUIPMENT
All tensioning equipment shall be procured from authorised manufacturers only and be
approved by the Engineer prior to use. Where hydraulic jacks are used, they shall be

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

power-driven unless otherwise approved by the Engineer. The tensioning equipment shall
satisfy the following requirements:

(i) The means of attachments of the pre-stressing steel to the jack or any other
tensioning apparatus shall be safe and secure.
(ii) Where two or more wires/strands constitute a tendon, a single multiple stressing
jack shall be used which is capable of tensioning simultaneously all the
wires/strands of the tendon. Suitable facilities for handling and attaching the multi-
pull back to the tendons shall be provided.
(iii) The tensioning equipment shall be such that it can apply controlled total force
gradually on the concrete without including dangerous secondary stresses in steel,
anchorage or concrete; and
(iv) Means be provided for direct measurement of the force by use of dynamo-metres
or pressure gauges fitted in the hydraulic system itself to determine the pressure in
the jacks. Facilities shall also be provided for the linear measurement of the
extension of pre-stressing steel to the nearest mm and of any slip of the gripping
devices at transfers.
All dynamometers and pressure gauges including a master gauge shall be calibrated by an
approved laboratory immediately prior to use and then at intervals not exceeding 3 months
and the true force determined from the calibration curve.
Pressure gauges shall be concentric scale type gauges accurate to within two per cent of
their full capacity. The minimum nominal size of gauge shall be 100 mm. The gauge shall
be so selected that when the tendon is stressed to 75 per cent of its breaking load, the
gauge is reading between 50 per cent and 80 per cent of its full capacity. Suitable safety
devices shall be fitted to protect pressure gauges against sudden release of Provision shall
be made for the attachment of the master gauge to be used as a check whenever requested
for by the Engineer.
Jack and pump shall be calibrated from approved laboratory prior to use and then at
intervals not exceeding six months.
2108 POST-TENSIONING
Tensioning force shall be applied in gradual and steady steps and carried out in such a
manner that the applied tensions and elongations can be measured at all times. The
sequence of stressing, applied tensions and elongations shall be in accordance with the
approved drawing or as directed by the Engineer.
It shall be ensured that in no case, the load is applied to the concrete before it attains the
strength specified on the drawing or as stipulated by the pre-stressing system supplier,
whichever is more.
After pre-stressing steel has been anchored, the force exerted by the tensioning equipment
shall be decreased gradually and steadily so as to avoid shock to the pre-stressing steel or
anchorage.

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

The tensioning force applied to any tendon shall be determined by direct reading of the
pressure gauges or dynamo-meters and by comparison of the measured elongation with the
calculated elongation. The calculated elongation shall be invariably adjusted with respect
to the modulus of elasticity of steel for the particular lot as given by the manufacturer.
The difference between calculated and observed tension and elongated during pre-
stressing operations shall be regulated as follows:
a) If the calculated elongation is reached before the specified gauge pressure is
obtained, continue tensioning till attaining the specified gauge pressure, provided the
elongation does not exceed 1.05 times the calculated elongation. If 1.05 times the
calculated elongation is reached before the specified gauge pressure is attained, stop
stressing and inform the Engineer.
b) If the calculated elongation has not been reached at the specified gauge pressure,
continue tensioning by intervals of 5 kg/sq. cm. until the calculated elongation is
reached provided the gauge pressure does not exceed 1.05 times the specified gauge
pressure.
c) If the elongation at 1.05 times the specified gauge pressure is less than 0.95 times the
calculated elongation, the following measures must be taken, in succession, to
determine the cause of this lack of discrepancy:
(i) Check the correct functioning of the jack, pump and leads.
(ii) De- tension the cable. Slide it in its duct to check that it is not blocked by
mortar which has through holes in the sheath. Re- tension the cable if free.
(iii) Re-establish the modulus of elasticity of steel for the particular lot from an
approved laboratory.
If the required elongation is still not obtained, further finishing operations such as
cutting or sealing, should not be undertaken without the approval of the Engineer.
d) When stressing from one end only, the slip at the end remote from the jack shall be
accurately measured and an appropriate allowance made in the measured extension
at jacking end.
A complete record of pre-stressing operations along with elongation and jack
pressure data shall be maintained in the approved format.
The number of stages of pre-stressing and grouting shall be reduced to a minimum,
preferably 2 in the case of simply supported girders.
2109 GROUTING OF PRE- STRESSED TENDONS
(1) GENERAL
The recommendations cover the cement grouting of post-tensioned tendons of pre-
stressed concrete members of bridges. This also covers some of the essential
protective measures to be adopted for minimising corrosion in PSC bridges.

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

The purpose of grouting is to provide permanent protection to the post-tensioned

steel against corrosion and to develop bond between the pre-stressing steel and the
surrounding structural concrete. The grout ensures encasement of steel in an alkaline
environment for corrosion protection and by filling the duct space, it prevents water
collection and freezing.

(2) MATERIALS
Water: Only clean potable water free from impurities conforming to Section 600
shall be permitted. No other water is to be used at all.
Cement: Ordinary Portland cement should be used for preparation of the grout. It
should be as fresh as possible and free of any lumps. Pozzolana cement shall not be
used.
Sand: It is not recommended to use sand for grouting of pre-stressing tendons. In
case the internal diameter of the ducts exceeds 150 mm, use of sand may be
considered. Sand, used, shall conform to IS: 383 and shall pass through IS Sieve No.
150. The weight of sand in the grout shall not be more than 10 per cent of the weight
of cement, unless proper workability can be ensured by addition of suitable
plasticizers.

Admixtures: Acceptable admixtures conforming to IS: 9102 may be used if tests

have shown that their use improves the properties of grout, i.e. increasing fluidity,
reducing bleeding, entraining air or expanding the grout. Admixtures must not
contain chlorides, nitrates, sulphides, sulphites or any other products which are likely
to damage the steel or grout. When an expanding agent is used, the total
unrestrained expansion should not exceed 10 per cent. Aluminium powder as an
expanding agent is not recommended for grouting because its long term effects are
not free from doubt.
Sheathing:
Sheathing shall fulfil requirement as specified in Section 2100
Grout openings or vents:
(a) All ducts should have grout openings at both ends. For this purpose special
openings should be provided where such openings are not available at end
anchorages. For draped (curved) cables vents shall be provided at all crown
and valley points. It is a good practice to provide additional air vents at
suitable intervals not exceeding 20 m. All grout openings or vents should
include provisions for preventing grout leakage.
(b) Standard details of fixing couplers, inlets, outlets and air vents to the
duct/anchorage shall be followed as recommended by the supplier of the pre-
stressing system.

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Ducts should be securely fastened at close intervals. All unintended holes or

openings in the duct must be repaired prior to concrete placing. The joints of the
couplers and the sheathing should be made water proof by use of adhesive tape or
similar suitable system capable of giving leak proof joints. Grout openings and vents
must be securely anchored to the duct and to either the forms or to reinforcing steel
to prevent displacement during concreting operations due to weight, buoyancy and
vibrations.
Ducts require very careful handling as, being of thin metal, they are susceptible to
leakage due to corrosion in transit or storage, by tearing/ripping in handling
particularly when placed adjoining to reinforcing steel, by pulling apart at joints
while inserting tendons prior to concreting, or by accidental puncturing while drilling
for form ties/inserts. Ducts are also liable to damage by rough use of internal
vibrator and sparks from welding being done close by.
(3) EQUIPMENT
(a) Grout Mixer and Agitator:
It is essential that the grout is maintained in a homogeneous state and of uniform
consistency so that there is no separation of cement. Use of grout mixers to obtain a
colloidal grout is essential. The mixer should have an additional storage device with
an agitator to keep the grout moving continuously before it is pumped in the duct.
Positive reciprocating type grout pumps should be used.
(b) Grout Pump:
The pump should be a positive displacement type and should be capable of ejecting
the grout in a continuous operation and not by way of pulses. The grout pump must
be fitted with a pressure gauge to enable pressure of injection to be controlled. The
minimum pressure at which grout should be pumped shall be 0.3 MPa and the grout
pump must have a relief arrangement for bypass of the grout in case of build-up of
pressure beyond 1 MPa. The capacity of the grout pump should be such as to
achieve forward speed of grout of around 5 to 10 metres per minute. The slower
rates are referable as they reduce the possibility of occurrence of voids. If the
capacity of the pump is large, it is usual to grout two or more cables simultaneously
through a common manifold.
Use of hand pumps for grouting, is not recommended. Use of compressed air
operated equipment for injection is prohibited, as it is likely that there will be some
air trapped in grout.
(c) Water Pump:
Before commencement of grouting, a stand by direct feed high pressure water pump
should be available at site for an emergency. In case of any problem in grouting the
ducts, such pump shall immediately be connected to the duct and all grout flushed by
use of high pressure water flushing. It is, therefore necessary to have adequate
storage of clean potable water for operation of the water pump for such emergencies.

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(d) Grout Screen:

The grouting equipment should contain a screen having a mesh size of 106 micron
size of 150 microns if sand is used). Prior to introduction into the grout pump, the
grout should be passed through such screen. This screen should be easily accessible
for inspection and cleaning.

(e) Connections and Air Vents:

Standard details of fixing inlets, outlets and air vents to the sheathing and/or
anchorage should be followed as recommended by specialist supplier of the system
of pre-stressing. In general, all connections are to be of the “Quick couple” type and
at change of diameters suitable reducers are to be provided.
(4) PROPERTIES OF THE GROUT
Water/cement ratio should be as low as possible, consistent with workability. This
ratio should not normally exceed 0.45. The temperature of grout shall not exceed 25o
C
Before grouting, the properties of the grout mix should be tested in a laboratory
depending on the facilities available. Tests should be conducted for each job
periodically. The recommended test is described below:
(a) Deleterious Materials:
No chloride, Sulphates shall be separately added to the grout. The constituent may
contain chlorides/sulphates. However, its net effect should not exceed the following
limits in the grout.
Chlorides (CI) not more than 0.1 percent by weight of cement
Sulphates (S03) not more than 4 percent by weight of cement
Sulphide-ions (s) not more than 0.01 percent by weight of cement
(b) Compressive Strength:
The compressive strength of 100 mm cubes of the grout shall not be less than 27
MPa at 7 days or 30 MPa at 28 days. Cubes shall be cured in a moist atmosphere for
the first 24 hours and subsequently in water. These tests shall be conducted in
advance to ascertain the suitability of the grout mix. The 7day strength is not
mandatory if the 28 day strength requirement is met.
(c) Setting Time:
Initial setting time of the grout shall be more than three hours and less than 12 hours.
The final setting time shall not be less than 24 hours.
(d) Bleeding:
Bleeding is the separation of free water from the grout mix. It includes the filtering
effect of strands where the cavities between the wires constituting the strand, block

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 STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

cement particles and permit water under pressure to move ahead of the grout in the
direction of general flow of grout. The bleeding shall be sufficiently low to prevent
excessive segregation and sediment of the grout material. The bleeding shall not
exceed 0.3 percent of volume of the initial volume of grout after three hours kept at
rest.

(e) Volume change

The volume change of grout kept at rest for 24 hours and tested as per ASTM C
1090 shall be within range of 1 % and 5 % of the original volume.
(f) Fluidity
Fluidity is tested as per ASTM C 939 standard using standard flow cone.
The fluidity of grout changes from time of mixing to time of setting in the ducts. The
requirement may be modified as per the specific application, depending upon the
total temperature, length of tendons, and head of pumping, requirement of
simultaneous grouting of closely spaced tendons etc. provided that other
specification and functions are satisfied.
(5) MIXING OF GROUT
Proportions of materials should be based on field trials made on the grout before
commencement of grouting, but subject to the limits specified above. The materials
should be measured by weight.
Water should be added to the mixer, first, followed by Portland cement and sand, if
used. Admixture if any, may be added as recommended by the manufacturer.
Mixing time depends upon the type of the mixer, but will normally be between 2 and
3 minutes. However, mixing should be for such a duration as to obtain uniform and
thoroughly blended grout, without excessive temperature increase or loss of
expansive properties of the admixtures. The grout should be continuously agitated
until it is injected.
Once mixed, no water shall be added to the grout to increase its fluidity.
Hand mixing is not permitted.
(6) GROUTING OPERATIONS
(a) General
Grouting shall be carried out as early as possible as but not later than 2 weeks of
stressing a tendon. Whenever this stipulation cannot be complied with for
unavoidable reasons, adequate temporary protection of the steel against corrosion by
methods or products which will not impair the ultimate adherence of the injected
grout should be ensured till grouting. The sealing of the anchorage ends after
concreting is considered to be a good practice to prevent ingress of water. For
structures in aggressive environment, sealing of the anchorage ends is mandatory.

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Notes:
i) Application of some patented water soluble oils for coating of steel/VPI
powder injection/sending in of hot, dry, oil-free compressed air through the
vents at frequent intervals have shown some good results.
ii) Some of the methods recommended for sealing anchorages are to seal the
openings with bitumen impregnated gunny bag or water proof paper or by
building a brick pedestal plastered on all faces enclosing the exposed wires
outside the anchorages.
iii) Any traces of oil if applied to steel for preventing corrosion should be
removed before grouting operation.
iv) Ducts shall be flushed with water for cleaning as well as for wetting the
surfaces of the duct walls. Water used for flushing should be of same quality
as used for grouting. It may, however, contain about 1 per cent of slaked
lime or quick lime. All water should be drained thorough the lowest vent
pipe or by blowing compressed air through the duct.
v) The water in the duct should be blown out with oil free compressed air.
Blowing out water from duct for cables longer than 50 m draped up at both
ends by compressed air is not effective, outlet/vent provided at or near the
lowest point shall be used to drain out water from duct.
vi) The connection between the nozzle of the injection pipe and duct should be
such that air cannot be sucked in.
vii) All outlet points including vent openings should be kept open prior to
commencement of injection grout.
viii) Before grouting, all air in the pump and hose should be expelled. The suction
circuit of the pump should be air-tight.
(b) Injection of Grout
After mixing the grout should be kept in continuous movement. Injection of grout
must be continuous and should not be interrupted. For vertical cable or cables
inclined more than 60 degrees to the horizontal, injection should be effected from the
lowest anchorage or vent of the duct.
The method of injection should ensure complete filling of the ducts. To verify this,
it is advisable to compare the volume of the space to be filled by the injected grout
with the quantity of grout actually injected.
Grouting should be commenced initially with a low pressure of injection of up to 0.3
MPa increasing it until the grout comes out at the other end. The grout should be
allowed to flow freely from the other end until the consistency of the grout at this
end is the same as that of the grout at the injection end. When the grout flows at the
other end, it should be closed off and building up of pressure commenced. Full
injection pressure at about 0.5 MPa shall be maintained for at least one minute

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before closing the injection pipe. It is recommended practice to provide a stand pipe
at the highest point of the tendon profile to hold all water displaced by sedimentation
or bleeding. If there is a built up of pressure much in excess of 1 MPa without flow
of grout coming at the other end, the grouting operation should be discontinued and
the entire duct flushed with high pressure water. Also, the bypass system indicated
in para 3.2 above is essential for further safety.
In the case of cables draped downwards e.g. in cantilever construction simultaneous
injection from both ends may be adopted. Grout not used within 30 minutes of
mixing should be rejected.
Disconnection is facilitated if a short length of flexible tube connects the duct and
injection pipe. This can be squeezed and cut off after the grout has hardened.
(7) PRECAUTIONS AND RECOMMENDATIONS FOR EFFECTIVE
GROUTING
(i) In cold and frosty weather, injection should be postponed, unless special
precautions are taken. If frost is likely to occur within 48 hours after injection,
heat must be applied to the member and maintained for at least 48 hours after
injection so that the temperature of the grout does not fall below 5 degrees
Celsius. Prior to commencement of grouting, care must be taken to ensure that
the duct is completely free of frost/ice by flushing with warm water, but not
with steam.
(ii) The temperature of the grout shall not exceed 25 degrees Celsius. For
increasing the workability of grout, its temperature may be lowered by use of
chilled water or by putting ice outside the grout storage container.
(iii) When the cables are threaded after concreting, the duct must be temporarily
stiffened during concreting by inserting bunch of strands, wires or
reinforcement or a rigid PVC pipe or any other suitable method.
(iv) During concreting, care shall be taken to ensure that the sheathing is not
damaged. Needle vibrators shall be used with extreme care by well
experienced staff only, to ensure against such damage.
(v) It is a good practice to move the cables in both directions during the concreting
operations. This can easily be done by light hammering the ends of the
wires/strands during concreting. It is also advisable that 3 to 4 hours after
concreting the cable should be moved both ways through a distance of about 20
cm. With such movement, any leakage of mortar which has taken place in
spite of all precautions, loses bond with the cables, thus reducing the chance of
blockages. This operation can also be done by fixing pre-stressing jacks, at one
end pulling the entire cable and then repeating the operation by fixing the jack
at the other end.
(vi) The cables to be grouted should be separated by as much distance as possible.

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(vii) In case of stage pre-stressing, cables tensioned in the first stage should not
remain ungrouted till all cables are stressed. It is good practice, while grouting
any duct in stage pre-stressing, to keep all the remaining ducts filled up with
water containing 1 per cent lime or by running water through such ducts till the
grout has set. After grouting the particular cable, the water in the other cables
should be drained and removed with compressed air to prevent corrosion.
(viii) Care should be taken to avoid leaks from one duct to another at joints of
precast members in particular.
(ix) End faces where anchorages are located are vulnerable points of entry of water.
They have to be necessarily protected with an effective barrier. Recesses
should be packed with mortar concrete and should preferably be painted with
water proof paint
(x) After grouting is completed, the projecting portion of the vents should be cut
off and the face protected to prevent corrosion.
(8) GROUTING RECORD
A record of grouting operations shall be maintained in the following format.
GROUTING RECORD
Job Name: ________________________________________
Span No. ______________________________ Cable No: _____________________
Date of Cable Installation: _______________ Date of Grouting: _______________
Type of Cement: OPC/ HSPC Week and Year of Manufacture of OPC/HSPC ---
W/C Ratio: ----------------- Name and amount of admixture used, if any:
Temperature: Mixing water ____________; Grout ___________________
Time: Start _____________; Finish ___________________
Equipment: Grout mixer ______________; Grout pump _______________
Cable duct: Diameter _______________; Length ___________________
Volume of grout in litres ________________; Regrouting ________________
Grouting pressure _____________________________:
Cement consumption: Theoretical ________________; Actual __________________
Pre-grouting checks:
Free of blockage Inlet: Yes/No Outlet : Yes/No
Vents: Yes/No Cable duct: Yes/No
Leakage observed: Yes/No Sealed: Yes/No
If cable duct blocked: Remedial Measures __________________________
Grouting observations:
Passage of grout through vents : Yes/No
Passage of grout through outlet : Yes/No
Any equipment failure : ______________
Post grouting checks :
Probing by stiff wire : ___________________________
Remarks : ___________________

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Signatures of officers present during grouting:

Client Contractor System Supplier

2110 PRE-TENSIONING
(1) General
The planning and construction aspects of the tensioning bed, tensioning bench,
abutments at location of anchorage, steam curing system, formwork of the concrete
elements and arrangements for demoulding, lifting, stacking and transportation of the
pre-tensioned concrete elements are all specialised items and shall be entrusted to
engineers specifically experienced in this type of work.
(2) Concrete Mix Requirements
Minimum cement content, maximum water cement ration and other durability
requirements shall be as indicated in Table 21.2 and minimum grade of concrete
shall be M 40.
Table 21.2: Requirement of Pre tensioned Concrete for different Exposure
Condition

Exposure condition Maximum water cement Minimum cement

ratio content kg/m3
Moderate 0.45 340
Severe 0.45 360
Very severe 0.4 380
(3) Form Work
All sides, bottoms and header forms shall be of steel or any other suitable material.
Forms shall be of sufficient thickness, with adequate external bracing and shall be
stiffened and adequately anchored to withstand the forces due to placement and
vibration of concrete. All joints of form work shall be leak proof. The bottom shutter
shall have arrangement to permit longitudinal movement of girder concrete, which
occurs while imparting pre-stress. Identifying marks shall be placed on the girders to
indicate the correct orientation to ensure correct debonding locations, which may not
be symmetrical, longitudinally.
(4) Laying of Deflected Tendons
For long span pre-tensioned girders, deflected tendons shall be used instead of the
conventional tendons. This requires the use of hold-up/hold-down devices at each
deflected location, in order to hold the tendons in the desired profile and location. A
hold-down device normally consists of rollers attached to a vertical rod, which
passes through the bottom form and is anchored to the form substructure or

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foundation to resist the pre-stress force. The force which must be resisted by the
hold-up/hold-down device, and therefore its size, depends on the number of
deflected strands and the trajectory angles of the strands. The strand can be either
tensioned after it is held in its deflected profile by means of hold-up/ hold-down
devices or it can be tensioned first and then brought into its deflected profile. The
number of deflected strands and their angle directly influence the size and cost of the
hold-up/hold-down devices.

(5) Compaction, Removal of Form Work and Curing

Compaction of concrete may be achieved through needle vibrators or form vibrators
along with needle vibrators. For casting of precast beams, any of the two commonly
known techniques of pre-casting viz. (1) long line method or (2) Short line method
may be used.
The girders shall not be moved from the casting location until stipulated strength
requirements have been attained. The concrete shall have attained a minimum
compressive strength of 20 MPa at the time of removal of forms. Curing of concrete
may be achieved through water or steam followed by water curing. Approved curing
compound may also be used.
Longitudinal movement of the girders that takes place while releasing the pre-stress
shall be suitably catered for in case of long line method of pre-casting, adequate
longitudinal gap shall be provided between girder ends during pre-casting, to
accommodate projecting reinforcement and required length of projecting strands.
(6) Stressing Bed for Pre-tensioning
The abutments and bed for pre-tensioning of tendons shall be designed to withstand
the total tensioning force.
A notice shall be displayed adjacent to the stressing bed showing the maximum
tensioning force permitted.
Where concrete elements are cast and pre-stressed individually, the stressed bench or
moulds shall be rigid enough to sustain the reaction of the pre-stressing force without
distortion.
In the long line method of pre-stressing, sufficient locator plates should be
distributed throughout the length of the bed to ensure that the wires are maintained in
their proper position during concreting. The moulds shall be free to slide in the
direction of their length and thus permit the transfer of the pre-stressing force to all
the concrete elements along the whole line.
Sufficient space shall be left in between the ends of concrete elements to permit
access for cutting the strands/wires after transfer. Hold-downs or deflectors shall be
used for holding or deflecting the tendons in required position firmly. Deflectors
which are in contact with the tendon shall have a diameter not less than the tendon or

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15 mm, whichever is greater.

The tensioning force required to be applied as stated on the drawings shall be the
force remaining in the strands/wires after all strands/wires have been anchored to the
abutments of the stressing bed and after the anchorage slip has already taken place.
The tensioning force shall be determined by direct reading of the pressure gauges or
dynamo-meters and by the measured elongation after slip.
The Contractor shall submit method of tensioning the tendons including the
arrangement and layout of pre-stressing beds and all tendon deflection points to the
Engineer for approval before manufacture commences. The Contractor shall carry
out trial stressing operations to establish the frictional resistance offered by the hold-
downs and the slip during anchoring.
Debonding of strands, wherever required, shall be carried out using HDPE
debonding tubes. PVC tubes shall not be permitted for this purpose. After pre-
tensioning the strands and before concreting, a recheck shall be made to ensure that
the debonding tubes are placed at the intended locations. Both ends of debonding
tubes shall be effectively sealed against ingress of any cement slurry using epoxy
putty or any other suitable material.
The Contractor shall also submit calculations showing that the hold-downs have
been designed and constructed to withstand concentrated loads resulting from the
application of the tensioning force.
(7) Pre-tensioning and De-tensioning Operations
(a) Pre -tensioning of Strands
Pre-tensioning of strands may be carried out either using single pull jack or multiple
pull jack. In case of the former, it shall be ensured at each stage, that the strands are
stressed symmetrically, so that the supporting system of the strands does not rotate or
distort. This may be achieved through suitably designed moving trolley engaging
the strands or any other suitable arrangements. Pre-stressing force shall be
transferred to metallic spacer, trolley etc. so that the force does not remain on the
hydraulic system for long.
It is necessary to apply a small pre-stressing force, through hydraulic jacks to remove
slackness of the strands. After removal of the slackness, the strands must be
thoroughly examined to ensure correct alignment, including that of the debonding
tubes. Reference marks for measuring elongation shall then be established and the
full strand load is applied thereafter. Loads indicated by the gauging system shall
control the tensioning, with elongation checked on every strand.
It shall be ensured that the entire length of the each strand between the grips is free
of any defects. This is of particular importance while pre-casting girders using long
line method entailing, longer pieces of stands between the grips.
Transfer of pre-stress shall not proceed until the Engineer has approved the proposed
method. Strands and deflection devices shall be released in such a pre-determined

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