Volume III LC 51 TD

KALYAN DOMBIVLI MUNICIPAL CORPORATION, KALYAN
Bidding Document
For
CONSTRUCTION OF APPROACHES TO PROPOSED

R.O.B. IN LIEU OF LEVEL CROSSING GATE –NO (51) AT
Km. 63/21-22 ON KYN-IGP SECTION BETWEEN
AMBIVALI AND TITWALA STATIONS. (WITH
CONTRACTORS OWN DESIGN AND DRAWINGS)
VOL. III
Specifications
Name of Work: Construction of Approaches to proposed R.O.B. in lieu of level
crossing gate no.51 at Km. 63/21-22 on KYN-IGP section between Ambivli &
Titwala railway stations (Manda - Titwala R.O.B.) (With contractors own Design
and Drawings).
INDEX
Description Page No.
1 Preamble 1
2 Technical Standards & Specifications
Part A General Technical Specifications 6
Part B Amendments / Modifications / Additions 6

to existing Clauses of General Technical
Specifications
Part C Additional Technical Specifications 49
Bidder 1 KDMC
and Drawings).
1 PREAMBLE
1.1 The Technical Specifications contained herein shall be read in conjunction with
the other Bidding Documents as specified in Volume-I.
1.2 Site Information
1.2.1 The information given hereunder and provided else wherein these documents is
given in good faith by the Employer but the Contractor shall satisfy himself
regarding all aspects of site conditions and no claim will be entertained on the
plea that the information supplied by the Employer is erroneous or insufficient.
1.2.2 The area in which the work is located is in plain/rolling terrain, and lies in Kalyan
Dombivali Municipal Corporation Region limits.
1.2.3 General Climatic Conditions
1.2.3.1 The temperature in this region is as under:
a) During summer months, the maximum temperature is 40 C
b) During winter months, the minimum temperature is 12 C
1.2.3.2 The average annual rainfall in the area is above 1500mm.
1.2.3.3 The exposure condition is classified as “severe” and all the necessary precautions
shall be taken.
1.2.4 Seismic Zone
The work is located in Seismic Zone-III as defined in IRC: 6-2014.
2 Technical Standards & Specifications
The Technical Specifications in accordance with which the entire work described
hereinafter shall be constructed and completed by the Contractor shall comprise
of the following:
Part A:-The General Technical Specifications shall be the “SPECIFICATIONS
FOR ROAD AND BRIDGE WORKS” (Fifth Revision, April, 2013) issued by the
Bidder 2 KDMC
and Drawings).
Ministry of Road Transport and Highways (formerly the Ministry of Surface

Transport) Government of India, and published by the Indian Roads Congress.
Where reference is made in the Contract to specific standards codes to be met by

the materials, plant, and other supplies to be furnished, and work performed or
tested, the provisions of the latest current edition or revision of the relevant
standards as on date of tender and codes in effect shall apply, unless otherwise
expressly stated in the contract. Where such standards and codes are national, or
relate to a particular country or region, other internationally recognized standards
which ensure a substantially equal or higher performance than the standards and
codes specified will be accepted subject to the Engineer in charge’s prior review
and written approval. Difference between the standards specified and the
proposed alternative standards must be fully described in writing by the Contractor
and submitted to the Engineer in charge at least 28 days prior to the date when
the Contractor desires the Engineer in charge’s approval. In the event the
Engineer in charge determines that such proposed deviations do not ensure
substantially equal performance, the Contractor shall comply with the standards
specified in the documents.
Part B -Amendments/Modifications/Additions to Existing clauses of General

Technical Specifications.
The Supplementary Technical Specifications shall comprise of various

Amendments/Modifications/Additions to the “SPECIFICATIONS FOR ROAD AND
BRIDGE WORKS” referred to in Part-A below and Additional Specifications for
particular item of works not already covered in Part-A
A particular Clause or a part thereof in “SPECIFICATIONS FOR ROAD AND

BRIDGE WORKS (Fifth Revision, April, 2013)”, as corrected in the original
referred in Part-A, where Amended/Modified/Added upon, and incorporated in
Part-B referred to above, such Amendment/Modification/Addition supersedes the
relevant Clause or part of the Clause.
The Additional Specifications shall comprise of specifications for particular items

of works not already covered in Part-A.
Bidder 3 KDMC
and Drawings).
When an Amended/Modified/Added Clause super cedes a Clause or part thereof

in the said Specifications, then any reference to the superseded Clause shall be
deemed to refer to the Amended/Modified/Added Clause or part thereof.
In so far as Amended/Modified/Added Clause may come in conflict or be

inconsistent with any of the provisions of the said MORT&H Specifications under
reference, the
Amended/Modified/Added Clause shall always prevail.
The following Clauses in the “SPECIFICATIONS FOR ROAD AND BRIDGE

WORKS (Fifth Revision, April 2013”) have been amended/modified/added upon:
1 1 2 108, 110, 111, 112,120, 200, 201,202, 300, 301, 305,

400,401,406,500,502,505,811, 901, 1000, 1007,1008,1009,1012,
1014,1015,11000,1101,1107,1200,1204,1205,1500,1503,1514,1515,
1600, 1002,1604,1605,1606,1607,1704,1705
1707,1708,1709,1711,1712,1801,1805
1807,1808,1809,1819,1900,2001,2005,2006,2011,2103,2106,2204,2305,
2504, 2602, 2703,2704,2833,2834
Bidder 4 KDMC
and Drawings).
PART C: - The Clauses SP-I to SP-14 have been added to the “Specifications for Road
and Bridge Works) Fifth revision, April 2013)
CLAUSE SP-1 PLANT AND EQUIPMENT FOR AGGREGATES AND

CONCRETE
CLAUSE SP-2 FIXING DOWEL BARS IN CONCRETE
CLAUSE SP-3 CURING USING LIQUID MEMBRANE FORMING COMPOUND
CLAUSE SP-4 ADDITIONAL TECHNICAL SPECIFICATIONS FOR ROAD SIGNS
CLAUSE SP-5 ADDITIONAL SPECIFICATIONS FOR TRAFFIC MANAGEMENT

AND DIVERSION
CLAUSE SP-6 SPECIFICATIONS FOR INTER-LOCKING CONCRETE PAVING

BLOCKS
CLAUSE SP-7 STREET LIGHTING INSTALLATION
CLAUSE SP-9 GEOTECHNICAL INVESTIGATIONS (DETAILED

EXPLORATION)
CLAUSE SP-10 ADDITIONAL SPECIFICATION FOR PROTECTIVE COATING

FOR CONCRETE
CLAUSE SP-11 SPECIFICATION FOR PRECAST CONCRETE SEGMENTAL

CONSTRUCTION
CLAUSE SP 12 REINFORCED EARTH WALL
CLAUSE SP 12 STRUCTURAL STEEL WORKS
CLAUSE SP-13 ENVIRONMENTAL MANAGEMENT PLAN
in the absence of any definite provisions on any particular issue in the afore said
Specifications, reference may be made to the latest codes and specifications of IRC, BIS,
BS, ASTM, AASHTO and CAN/CSA in that order. Where even these are silent, the
construction and completion of the works shall conform to sound engineering practice as
Bidder 5 KDMC
and Drawings).
approved by the Engineer in charge and in case of any dispute arising out the
interpretation of the above, the decision of the Engineer in charge shall be final and
binding on the Contractor.
Part A:-The General Technical Specifications shall be the “SPECIFICATIONS FOR

ROAD AND BRIDGE WORKS” (Fifth Revision, April, 2013) issued by the Ministry of
Road Transport and Highways (formerly the Ministry of Surface Transport) Government
of India, and published by the Indian Roads Congress.
PART B AMENDMENTS/MODIFICATIONS/ADDITIONS TO EXISTING CLAUSES

OF GENERAL TECHNICAL SPECIFICATIONS
SECTION 100 GENERAL CLAUSE 102 DEFINITIONS

(Addition) The following abbreviations shall be added in this Clause:
"MORTH”: Ministry of Road Transport and Highways
“KDMC”: Kalyan Dombivali Municipal Corporation.
CLAUSE 108:- SITE INFORMATION
Clause 108.4:- Add following after cl 108.3:
(Addition) “Identification of quarry sites and borrow areas shall be the
responsibility of the Contractor. Materials procured from quarry
sites and borrow areas identified by Contractor and to be used in
Works must comply with the requirements of quality as stipulated in
the Technical Specification for particular items of work.”
CLAUSE 110:- PUBLIC UTILITIES
Add following at the end of 110.2
Clause 110.2:- The contractor will make necessary payments to the respective
service provider/authorities for shifting of utilities, wherever required
and also in cases where payments are not required to be made for
such shifting.
Clause 111:- Precautions for Safeguarding the Environment
Add the following new Sub Clauses 111.14 to 111.23.
Clause 111.14:- Dust Control during Construction
Bidder 6 KDMC
and Drawings).
The Contractor shall make adequate provision, including frequent

spraying of water, to mitigate dust nuisance from on-site equipment
during the construction of the works.
Clause 111.15:- Sanitation
The Contractor shall make adequate sanitation facilities for labour
and Contractor’s camp, including provision of lavatories, sewage
disposal, and solid waste collection and disposal.
Sub-Clause 111.16:- Water Sources and Water Quality

The Contractor shall provide independent sources of water supply,
such as bore wells, for use in the Works and for associated
storage, workshop and work force compounds. Prior approval shall
be obtained from the relevant State Authorities and all installations
shall be in compliance with local regulations. Bore wells installed
and used for the project shall be left in good operating condition for
the use of local communities. The Contractor shall prevent any
interference with the supply to or abstraction from, and prevent any
pollution of water resources (including underground percolating
water) as a result of the execution of the Works.
Areas where water is regularly or repetitively used for dust
suppression purposes shall be laid to fall to specially constructed
settlement tanks top permit sedimentation of particulate matter.
After settlement, the water may be re-used for dust suppression
and rinsing. The Contractor shall protect all watercourses,
waterways, ditches, canals, drains, lakes and the likes from
pollution as a result of the execution of the Works. All water and
other liquid waste products arising on the Site shall be collected
and disposed of at a location on or off the Site and in a manner that
shall not cause either nuisance or pollution.
The Contractor shall at all times ensure that all existing stream
courses and drains within, and adjacent to, the Site are kept safe
and free from any debris and any materials arising from the Works.
The Contractor shall not discharge or deposit any matter arising
from the execution of the Works into any water except with the
Bidder 7 KDMC
and Drawings).
permission of the Engineer in charge and the regulatory authority

concerned.
Work force camps shall have septic tank and soak away pits.
Operational areas like POL storage areas/hot mix plant areas shall
comply with local/state environmental regulations and safety
procedures. Storage and handling areas shall be impervious and
surrounded by an impervious lined drain to catch any accidental
spills. Storm water shall be stored in lined holding tanks with oil,
grease-tapping facility prior to disposal in to nearby watercourses.
The trappings and sludge of holding tanks shall be disposed off in
accordance with the procedures approved by the local regulatory
authority.
Sub-Clause 111.17:- Equipment and Vehicles used for the Works
Equipments and vehicles deployed for the construction activities
shall not be older than 5 years. Equipments used for road and
bridge works shall be based on new technology and shall generate
noise and pollutants not exceeding the limits specified by the
relevant State Authorities. Vehicles and machineries used for road
and bridge works are to be regularly maintained to conform to the
National Air Quality Standards.
Sub-Clause 111.18:- Noise Control:-
The Contractor shall consider noise as an environmental constrain
in the planning and execution of the Works.
The Contractor shall take all necessary measures so that the
operation of all mechanical equipment and construction processes
on and off the site shall not cause any unnecessary or excessive
noise, taking in to account applicable environmental requirements.
The Contractor shall use all necessary measures and shall
maintains all plant and silencing equipment in good conditions so
as to minimize the noise emission during construction works.
Any member of the work force likely to be exposed to beyond their
threshold noise levels shall be provided with protective equipment,
such as earplugs, and shall be rotated every four hours.
Bidder 8 KDMC
and Drawings).
Sub-Clause 111.19:- Vibration Control

The Contractor shall take measures during construction activities to
control the movement of the work force and construction
machinery/equipment, and to avoid/ minimize activities, which
produce vibrations.
Sub-Clause 111.20:- Construction Camps
The construction camps shall conform to the State and National
building regulations as applicable. The area for the storage of
polluted materials shall be stored on impervious floors and shall be
surrounded by impervious ditches in order to avoid spilling of
polluted material to surrounding areas.
Construction camps shall be properly arranged to avoid noise
pollution to the nearby habitants and to avoid contamination of river
and canals from wastewater drainage. To prevent such
contamination, wastewater generated at the campsites shall be
discharged in to soak pits. These shall be of sufficient capacity to
contain 120% of estimated volume. These shall be regularly
cleaned and maintained to be effective. Human excreta shall be
treated though septic tanks prior to discharge and shall conform to
directives and guidelines of the State. Water accumulated in tires,
empty vessels and containers of all nature will be regularly cleaned
to avoid the related health hazards.
Sub-Clause 111.21 Control and Disposal of Wastes
The Contractor shall control the disposal of all forms of waste
generated by the construction operations and in all associated
activities. No uncontrolled deposition or dumping shall be
permitted. Wastes to be so controlled shall include, but shall not be
limited to, all forms of fuels and engine oils, all types of bitumen,
cement, and surplus aggregates, gravels, bituminous mixtures etc.
The Contractor shall make specific revision for the proper disposal
of these and any other waste products, conforming to local
regulations and acceptable to the Engineer in charge.
Bidder 9 KDMC
and Drawings).
Spilling of oil and bituminous products during construction and

transport shall be avoided to reduce the chances of contamination
of surface as well as ground water.
Degraded materials shall be disposed of in a manner as approved
by the Engineer in charge and wastewater shall be disposed into
septic tanks and soak pits etc. The Contractor shall make
arrangements to cleanup spoil as soon as the work finishes in a
stretch. If such sites are located outside the ROW, restoration of
the site to a level acceptable to the land owner swill be carried out
within a time period agreed between landowner(s) and the
Contractor. Separators shall be used to separate POL materials
from wastewater prior to discharging to the watercourses or as
approved by the Engineer in charge in conformance with directives
and guidelines.
Disposal of solid waste materials shall be outlined in a plan for
which environmental clearances shall be obtained from State
environmental regulatory authorities. Potential locations for solid
waste disposal are the natural depressions and borrow areas. The
areas used for dumping of uncontaminated debris shall be covered
with 300mm soil and shall be planted. Contaminated debris shall be
dumped in depressions whose bed must be impervious e.g., stone
quarry sites or depressions made impervious with 450mm thick
impervious floor apron as per MORTH Technical Specifications.
Each successive 1.0m layers shall be covered with 500mm thick
soil layer, and the area will be covered with 300mmthick layer and
planted.
Sub-Clause 111.22: -Transport of Hazardous Materials
Transport of al hazardous materials, in bulk or in sealed containers,
shall meet the requirements of the State regulations. Prior to
ordering transport of hazardous material in bulk, the Contractor
must obtain the approval of the relevant authority as well as of the
Engineer in charge. Precautionary measures and conformity with
regulations shall be stated in a Method Statement for the approval
of the Engineer in charge. Sealed containers of hazardous
Bidder 10 KDMC
and Drawings).
materials shall be stored in a well-ventilated room, well-guarded

and secured
Sub-Clause 111.23: -Emergency Response
The Contractor shall plan and provide remedial measures to be
implemented in the event of occurrence of emergencies such as
spillages of oil or bitumen or chemicals. The Contactor shall
provide the Engineer in charge with a statement of the measures
he intends to implement in the event of such an emergency, which
shall include a statement of how he intends to provide personnel
adequately trained to implement such measures.
CLAUSE 112: - ARRANGEMENT FOR TRAFFIC DURING CONSTRUCTION
Clause 112.4: - Traffic Safety and Control
Add the following para in the end of Clause 112.4:
The Contractor shall be fully responsible for the adequate safety of
all site operations and methods of construction.
Persistent breaches of the safety provisions by the Contractor and
his employees shall constitute a sufficient cause for action.
The Contractor shall also observe the following additional safety
provisions. Before taking up, an agreed phased programme for
providing barricades of the approved design as per drawings and
other safety measures shall be drawn in consultation with the
Engineer in charge.
1.1.3.1 The barricading shall be erected on either side of the
carriageway portion/ portion of the carriageway where any
construction activity is taken up on or alongside of the existing
carriageway.
1.1.3.2 Flagmen in adequate numbers shall be provided to marshal
the traffic on diversion wherever diversion of traffic is resorted to.
1.1.3.3 Proper traffic signage in required numbers shall be provided
for the information of road users.
1.1.3.4 A safety officer shall be nominated to prepare safety
programme and oversee the safety arrangements at site.
Bidder 11 KDMC
and Drawings).
E 120 FIELD LABORATORIES

Clause 120.2 Description
(Modification /Addition /
Substitution) Add the words “uninterrupted in third line of first paragraph
before “amenities like --------water supply”
Replace the words “indicated in the drawings” in the first sentence
of second paragraph of this Clause with the words “per provisions
indicated in this clause and at a location approved by the Engineer
in charge.”
Add at the end of paragraph:
i). The uninterrupted power/water supply etc. shall be ensured to
the laboratory
.ii). The floor space required for the field laboratory shall be not less
than500 Sq.m.
iii). A good semi furnished office accommodation shall be provided
to the Material Engineers of the Supervision Team as per the
direction of the Engineer in charge.
iv). There shall also be provided a concrete paved area, for storing
samples adjacent to the laboratory, of about 300 Sq.m and
another200 Sq.m suitably roofed with open sides giving protection
against sun and rain.
v). Within 14 (fourteen) days of the commencement date, the
Contractor shall prepare and submit a layout plan and details of the
laboratory building and make/supplier of the equipment to the
Engineer in charge for his approval.
vi). The field laboratory to be provided under the Contract shall be
handed over to the Engineer in charge in finished and fully
equipped condition not later than 2 months after the receipt of
Notice to Commence Work, and the field laboratory with all
equipment/ instrument shall be to the entire satisfaction of the
Engineer in charge. During the 2 month period starting from the
Notice to Commence work, the laboratory tests shall be performed
in another laboratory proposed by the Contractor and approved by
the Engineer in charge.
Bidder 12 KDMC
and Drawings).
SECTION 200 SITE CLEARANCES

CLAUSE 201 CLEARING AND GRUBBING Clause 201.1 Scope
(Addition) Add the following at the end of this clause:
"After cutting/trimming of trees, the wood shall be the property of
the Employer and shall be carted and stacked as directed by the
Employer."
CLAUSE 202:- DISMANTLING CULVERTS, BRIDGES AND OTHER
STRUCTURES/ PAVEMENTS
Clause 202.5:- Disposal of Materials
(Modification) These Clauses shall read as under
All materials obtained from dismantling structures including houses/
bungalows etc., shall be the property of contractor and shall be
removed and disposed off as per directions of Engineer in charges.
SECTION 300:- EARTHWORK, EROSION CONTROL AND DRAINAGE

CLAUSE 301:- EXCAVATION FOR ROADWAY AND DRAINS
Sub-Clause 301.2:- Classification of Excavated Material
Sub-Clause 301.2.1:-Classification
Add at the end of Para (a)
“Conglomerates and boulders not requiring blasting having
maximum dimension in any direction upto 300mm shall also be
covered under this category”
Delete “and conglomerates” from first line of Para b (i).
Sub-Clause 301.3.5:-Rock Excavation
The first sentence of first Para shall read “Rock, when encountered
in road excavation, shall be removed upto a level of 100mm below
the base of WMM.”
Sub-Clause 301.3.7:-Excavation of road shoulders/verge/medians for widening of

pavement or providing treated shoulders
The title of this Clause shall read as under:
Bidder 13 KDMC
and Drawings).
"Excavation of road shoulders/verge & medians for widening of

pavement or for providing treated/paved shoulders and medians”.
The first sentence of this Clause shall be replaced as under:
“In works involving pavements, the existing
shoulders/verge/median shall be removed to its full width and upto
top of subgrade. The exposed subgrade top shall be tested for field
compaction and 4-day soaked CBR at 97% of MDD. If the field
compaction is more than 97% of MDD and 4-days soaked CBR
at97% MDD is satisfying the Design CBR, then the surface shall be
prepared as per Clause 401.4.1.If the field compaction is less than
97% of MDD,but4-days soaked CBR at 97% MDD is satisfying the
Design CBR, then the subgrade material within 0.5m from the
lowest part of the pavement crust for widened portion or paved
shoulders shall be loosened and recomputed as per Clause 305 to
a density not less than 97% of maximum dry density determined
according to IS:2720 (Part 8). Any unsuitable material (soaked
CBR at 97% MDD less than design CBR) encountered in this
portion of sub-grade shall be removed and replaced with suitable
material and compacted in accordance with Clause 305”.
Clause 301.3.11: - Use and Disposal of Excavated Materials
Replace the Sub-Clause by the following:
All the excavated materials shall be the property of the employer.
The materials obtained from the excavation of roadway, shoulders,
verges, drains, cross drainage works etc. shall be used for filling up
of (i) (ii) The existing pits in the right-of-way (iii) sub-grade (iv)
pavement (v) rock fill embankment. (vi) for crushing into
aggregates(ix) for landscaping of the road as directed by the
Engineer in charge, including leveling and spreading with all lead
and lifts.
Unsuitable and surplus materials if found in any stretch shall be
disposed off with all lifts and leads as directed by the Engineer in
charge with no extra payment.
Bidder 14 KDMC
and Drawings).
CLAUSE 304 EXCAVATIONS FOR STRUCTURES

Sub-Clause 304.3.2: - Excavations
At the end of 1paragraph of Sub Clause 304.3.2 insert the following
additional sentences:
“The Contractor shall ensure the stability and structural integrity of
adjacent existing foundations and structures and if necessary,
shall, at his own expense, install temporary or permanent sheet
piles, coffer dams, shoring or similar as support or protection to the
satisfaction of the Engineer in charge.”
CLAUSE 305: - EMBANKMENT CONSTRUCTIONS
Clause 305.2.2.2: - Borrow Materials

(Modifications) add following at the end of this clause
"No borrow area shall be made available by the Employer for this
work. The arrangement for the source of supply of the material for
embankment and subgrade as well as compliance to the different
environmental requirements in respect of excavation and borrow
areas as stipulated, from time to time, by the Ministry of
Environmental and Forest, Government of India and the local
bodies, as applicable, shall be the sole responsibility of the
Contractor. No earth, except when the road is in cutting, shall be
borrowed from the Right of Way.”
The above information shall form the basis for compaction only
uponits approval by the Engineer in charge.”
Bidder 15 KDMC
and Drawings).
Sub-Clause 305.2.2.4:- Compaction Requirements

Delete Table 300-2 and substitute the following:
Table 300-2
Compaction Requirements of Embankment and Subgrade
Sl. No. Type of Work/Material Relative Compaction as %age of

No maximum laboratory dry
density as per IS 2720 (Part 8)
1 Subgrade and earthen Not less than 97%

shoulders
2 Earthwork (height upto 6 m) Not less than 95%
3 Earthwork (height upto 6 >m) Not less than 97%
4 Expansive clays Not allowed
Sub-Clause 305.3: - Construction Operations

Sub-Clause 305.3.1: - Setting out
Add the words “minimum 300 mm” after the words “sufficiently”
appearing in the fourth line of this clause.
Sub-Clause 305.3.4: - Compacting Ground Supporting
Embankment/Subgrade
Para 1 of this clause shall be read as under:
“The original ground shall be leveled, scarified, mixed with water
and then compacted by rolling to facilitate placement of first layer of
embankment so as to achieve minimum dry density as given in
Table 3002”.
Add at the end of Para 2
” Backfilling layers in pits, trenches and below the original ground
are to be compacted to the relative natural ground density. The
natural ground density shall be determined by conducting field
density tests at three widely spaced locations along the central line
of the proposed/widened carriageway at a depth between 0.5m to
1.0m. Samples of natural ground are collected at each location,
Bidder 16 KDMC
and Drawings).
and are tested in accordance with IS: 2720(Part 8). The relative
density (i.e. the percentage of the field dry density to the laboratory
maximum dry density) is assessed for each sample, and the
greatest relative density obtained is selected as the “natural ground
density”. If the natural ground density is less than 85% then these
are to be compacted after necessary watering so as to achieve not
less than 85% of relative compaction”.
“Where necessary to facilitate compaction of the subgrade to
97%relative compaction as stated above, a further depth below the
subgrade of maximum thickness of 0.2m shall be loosened,
watered and compacted in accordance with Sub Clause 305.3.5
and 305.3.6 to not less than 95% of dry density determined in
accordance with IS: 2720(Part-I)”.
Sub-Clause 305.3.6: - Compaction
The second Para of this Clause shall read as under:
"The compaction shall be done with the help of self-propelled single
drum vibratory roller or pad foot vibratory roller of not less than 80-
100KN static weight with plain or pad foot drum or pneumatic tyre
roller of300 KN weight having tyre pressure of at least 7 kg/sqcm
shall be used for compaction.”
Insert the following sentence before the last sentence of Paragraph
5. “The co-relation between sand replacement densities and
nuclear gauge densities shall be based on trials with minimum 30
coherent density measurements”.
Sub-Clause 305.4.6: - Add the following at the end of Sub Clause
In section/ reaches where Re Wall has to be constructed on
marshy or boggy/ water logged soils, coarse sand blanket layer
(>75 micron) of minimum 500mm thickness shall be laid before
taking up the construction of embankment. The provision of this
blanket layer of sand is payable separately.
SECTION 400: - SUB-BASES, BASES (NON-BITUMINOUS) AND SHOULDERS
General
Bidder 17 KDMC
and Drawings).
Sub clause (i) of clause 401.7 stands deleted and remaining sub
paras
(ii) to (v) are renumbered as (i) to (iv).
Sub clause (i) of clause 405.7.1 stands deleted and remaining sub
paras (ii) to (iv) are renumbered as (i) to (iii).
The provision of clause 401.7 (i) to (v) be read as “Clause 401.7 (i)
to (iv)” in the sub clauses 402.8, 403.8, 404.7 and 407.7.
CLAUSE 401: - GRANULAR SUB BASE
Sub Clause 401.3: - Construction Operations
Add the following below this sub clause:
“The Contractor shall carry out laying trials, to demonstrate that the
proposed mix can be successfully laid and compacted. The laying
of trial shall be carried out on a suitable area which is not to form
part of the works. The area of the laying trials shall be a minimum
of 1000 Sq.m. Of construction similar to that of the project road,
and it shall be in all respects, particularly compaction, the same as
the project construction, on which the granular sub base is to be
laid.
The Contractor shall give prior information to the Engineer in
charge the proposed method for laying and compacting the
material. The plant trials shall then establish if the proposed laying
plant, compaction plant, and methodology is capable of producing
satisfactory results. The density of the finished paving layer shall be
determined by taking cores, no sooner than 24 hours after laying,
or by other approved method.
Once the laying trials have been approved, the same plant and
methodology shall be applied to the laying of the material on the
project, and no variation shall be acceptable, unless approved in
writing by the Engineer in charge, who may at his discretion require
further laying trials.
CLAUSE 406: - WET MIX MACADAM SUB BASE/BASE
Sub-Clause 406.2.1.1: -Physical Requirements
Bidder 18 KDMC
and Drawings).
Delete the second sentence beginning with "If crushed gravel…”

and ending with “…. fractured faces." and add as under:
“If crushed boulders are used, not less than 90% by weight of
crush boulders retains on 4.75mm sieve shall have at least two
fractured faces.
The constituents of the aggregates shall be produced by integrated
crushing and screening plant and, unless otherwise instructed by
the Engineer in charge, crushing shall be carried out in at least two
stages. The fraction of material passing through 4.75mm sieve
shall also be crusher run screening only.”
Add the following at the end of the paragraph:
Soundness test shall be carried out in accordance with IS : 2386
(Para 5)1963. The average loss of weight of coarse aggregate after
"5 cycles shall not exceed 12% when tested with sodium Sulphate
and 18% when tested with magnesium Sulphate as specified in IS:
383.
Sub-Clause 406.3: - Construction Operations
Add the following below this sub clause:
“The Contractor shall carry out laying trials, to demonstrate that the
proposed mix can be successfully laid, and compacted. The laying
of trial shall be carried out on a suitable area which is not to form
part of the works. The area of the laying trials shall be a minimum
of 1000 Sq.m. Of construction similar to that of the project road,
and it shall be in all respects, particularly compaction, the same as
the project construction, on which the granular sub base is to be
laid.
The Contractor shall previously inform the Engineer in charge of
the proposed method for laying and compacting the material. The
plant trials shall then establish if the proposed laying plant,
compaction plant, and methodology is capable of producing
satisfactory results. The density of the finished paving layer shall be
determined by taking cores, no sooner than 24 hours after laying,
or by other approved method.
Bidder 19 KDMC
and Drawings).
Sub-Clause 406.3.3:-Preparation of Mix

Delete the first sentence beginning with "Wet Mix Macadam…” and
ending with “…. Concrete batching plant." and add as under:
“Wet mix Macadam shall be prepared in an approved Wet Mix
Macadam mixing plant of 200T/hour capacity having provision for
controlled addition of water and forced/positive mixing
arrangement.”
Sub-Clause 406.3.4: Spreading of Mix
Substitute Para 2 by the following:
“The mixing shall be spread only by paver finisher for the main
pavement under the carriageway and shoulders. In exceptional
cases where it is not possible for the paver to be utilized,
mechanical means, like motor grader, may be used with the prior
approval of Engineer in charge.”
Clause 406.3.5: - Compaction
Delete second sentence of Para 1 of Clause 406.3.5.
SECTION 500: - BASE AND SURFACE COURSES (BITUMINOUS)
Replace entire 502, 503, 504, 507, 508 510 with the following;
CLAUSE 502: - PRIME COAT OVER GRANULAR BASE
Sub-Clause502.2: - Materials
Sub-Clause502.2.2: - Quantity of SS1 grade bitumen emulsion for various types of

granular surfaces shall be as given in Table 500-3.
Table 500-3: Quantity of Bitumen Emulsion for Various Types

of
Granular Surfaces
Types of Surface Rate of Spray (Kg per Sq.m)
WMM/WBM 0.80
Stabilized soil bases/Crusher Run 1.00
Macadam
Bidder 20 KDMC
and Drawings).
Sub-Clause 502.2.3: - Cutback for primer shall not be prepared at the site. Type
and quantity of cutback bitumen for various types of granular surface shall be as given in
Table 500-4.
Table 500-4: Type and Quantity of Cutback Bitumen for Various

Types of Granular Surfaces
Types of Surface Type of Rate of Spray
Cutback (Kg per Sq.m)
WMM/WBM MC 30 0.80
Stabilized soil bases/Crusher MC 70 1.00
Run Macadam
Sub-Clause502.3: - Weather and Seasonal Limitations

Primer shall not be applied during a dust storm or when the
weather is foggy, rainy or windy or when the temperature in the
shade is less than 10C. Cutback bitumen as prime coat shall not be
applied to a wet surface. Surfaces which are to receive emulsion
primer should be damp, but no free or standing water shall be
present. Surface can be just wet by very light sprinkling of water.
TACK COAT
Sub-Clause 503.4.3 Application of tack coat
The application of tack coat shall be at the rate specified in Table
500-5, and it shall be applied uniformly. No dilution or heating at
site of RS1bitumen emulsion shall be permitted. Paving bitumen if
used for tack coat shall be heated to appropriate temperature in
bitumen boilers to achieve viscosity less than 2 poise. The normal
range of spraying temperature for a bituminous emulsion shall be
20C to 70C and for cutback, 50C to 80C. The method of application
of tack coat will depend on the type of equipment to be used, size
of nozzles, pressure at the spray bar, and speed or forward
movement. The Contractor shall demonstrate at a spraying trial,
Bidder 21 KDMC
and Drawings).
that the equipment and method to be used is capable of producing

a uniform spray, within the tolerances specified.
Table 500-5: Rate of Application of Tack Coat
Types of Surface Rate of Spray (Kg per Sq.m)
Bituminous Surface 0.20
Granular surface treated with primer 0.25
Cement concrete pavement 0.30
CLAUSE 504: - BITUMINOUS MACADAM

Sub-Clause 504.2: - Materials
Sub-Clause 504.2.1: - Bitumen
The bitumen shall be viscosity graded VG-30 bitumen complying
with Indian Standard Specification for bitumen, IS:73. Guidelines
for selection of bitumen are given in Table 500-1.
Clause 504.2.2: - Coarse Aggregates
Delete the words from 2nd line of 1st Para “Crushed gravel or other
hard material retained on the 2.36mm sieve”.
Delete the entire Para 3 of Clause 504.2.2
Additional Specification:
i) Modern drum mix plant and paver finisher with electronic sensing
device conforming to Clause no. 504.3.4 and 504.3.5 of
M.O.R.T&H specification 2001 shall be used for the work
ii) The Contractor shall work out the super elevation required before
laying bituminous layer. The bituminous layer shall provide the
required super elevation accordingly.
CLAUSE 505: - DENSE BITUMINOUS MACADAM
Clause: 505.2.2: - This clause shall read as under
i) Delete the words from 2nd line of 1st para “Crushed gravel or
other hard material retained on the 2.36mm sieve”.
ii) Delete the entire Para 2 of Clause 505.2.2
Bidder 22 KDMC
and Drawings).
Clauses 505.3.3
(Modification) Insert the following paragraph between existing paragraph 3 and
4Mixdesign shall be carried out in accordance with the modified
Marshall method described in Asphalt Institute Manual MS – 2.
CLAUSE 811: - CONCRETE CRASH BARRIER Clause 8011.2.1.2 Replace “M

25 by M-40”
Clause 901.15: - Site Trial
(Additional) The Contractor shall carry out full-scale site trials on all earthwork
and pavement items proposed for the Works using the equipment
and methods proposed by the Contractor for constructing the
Works. The trials shall be carried out with the agreement and in the
presence of the Engineer in charge or his authorised
representative.
The trials shall be carried out to enable the Contractor to
demonstrate the suitability of his mixing and/or compaction
equipment to provide the specified material and compact the same
to the specified density and to confirm that the other specified
requirements of the completed earthworks and pavement courses
can be achieved.
Each trial area shall be at least 1000 (approx. 15m x 75m length)
square meters and shall be laid to the specified depth for the
material. It may form part of the works if so, ordered by the
Engineer in charge provided it complies with the specification. Any
trial areas, which do not comply with the Specification, shall be
removed. The Contractor shall allow in his programme for
conducting site trials and for carrying out the appropriate tests on
them. The trials on earthworks and each pavement layer shall be
undertaken at least 14 days ahead of the Contractor proposing to
commence full scale work on earthworks and the pavement layers.
The following data shall be ordered at each site trial:
 The composition and grading of the material, including the bitumen

content and properties, if appropriate;
Bidder 23 KDMC
and Drawings).
 If appropriate, the moisture content at the time of laying;

 If appropriate, the temperature at the time of laying and rolling;
 The type and size of compaction equipment and the number of
passes
 The maximum density or target density as appropriate and the
density achieved in the trial;
 The maximum compacted thickness of layer;
 The surface levels and the surface irregularities
 Calibration of machinery for TMC and efficient results;
 Any other relevant information
Not less than ten sets of tests for each type of test shall be made on
each 500 square meters of trial area, and provided nine out of ten sets
of results meet the specified requirements for the material/work in
Clause 903, the site trial shall be deemed successful. The above data
recorded in the trial shall become the agreed basis on which the
particular material shall be provided and processed to achieve the
specified requirements.
If, during execution of the Works, the construction control type of tests
indicates that the requirements for a material are not consistently being
achieved, then work on that layer shall stop until the cause is
investigated. Such investigation may include further laboratory and site
trials on the material to determine a revised set of data, as above
which, when agreed by Engineer in charge, shall be the basis on which
all subsequent material will be provided and processed to achieve the
specified requirements.
Approval by the Engineer in charge to a set of data recorded, as above
in a site trial shall not relieve the Contractor of responsibility to comply
with the requirements of Technical Specifications.
SECTION 1000: - MATERIALS FOR STRUCTURES
CLAUSE 1007: - COARSE AGGREGATES
Delete “crushed gravel, natural gravel, or a suitable combination
there of other approved material inert material” in 3and 4line of
Bidder 24 KDMC
and Drawings).
1Para and replace with “or crushed boulders. For this purpose,
boulder greater than average dimension of 300 mm shall only be
used.”
Add the following at the end of Para 2.
“Costs of all tests shall be borne by the Contractor.”
Add the following at the end of the Clause:
"Integrated stone crusher with Primary and Secondary (Cone or
ImpactType) crushers shall be employed for getting proper size and
grading ofcoarse aggregates."
The alkali aggregate reactivity should be measured and reported
for getting approval for the source aggregates at the beginning of
the workusing methods given in IS: 2386. The tests may be
repeated if the source, or the type of rock being exploited for
getting aggregates, changes.
CLAUSE 1008 FINE AGGREGATES
Delete from the 2line the word “gravel” in Para 2.
Add the following at the end of the clause:
“The alkali aggregate reactivity shall be measured and reported for
getting approval for the source.”
Sub-clause 1009.3 Reinforcement/ Un-tensioned steel
In the Table 1000.3, replace “IS: 1786 High Yield Strength
Deformed bars (HYSD)” with “IS: 1786 Thermo Mechanically
Treated (TMT) Highstrength deformed bars)”. Any other reference
to “HYSD” bars in thespecifications shall be read as “TMT” bars.
Replace Grade Designation S415 by Fe 500 and characteristic
strength fy MPa as 500.
Delete last Para of the clause.
CLAUSE 1012 CONCRETE ADMIXTURES CLAUSE 1012.3
Sub-Clause 1012.1 Add the following at the end of paragraph 1:

Admixtures shall not impair the durability of concrete; they shall not
combine with the ingredients to form harmful compounds or
endanger the protection of reinforcement against corrosion. Only
chloride free admixtures shall be used.
For all admixtures being used the packing shall be marked with the
name of the supplier/manufacturer, brand name (name of product)
and maineffect. A certificate for the admixture in question shall be
submitted. Thecertificate shall include the following information:
Bidder 25 KDMC
and Drawings).
A) General
Chemical name of the active component in the admixture.
Values of dry material content, ash content and relative

density of admixture, which can be used for uniformity tests.
Chloride ion content expressed as a percentage of weight of
cement.
pH value and colour.
Normal side effects e.g. whether the admixture leads to air
entrapment at recommended dosage and if so to what
extent.
Side effect when overdosed.
If two or more admixtures have to be used in one mix, their
compatibility.
Increase in risk of corrosion of reinforcements and
embodiments due to the use of admixtures.
Latest date of test and name of test laboratory.
B) Storing
C) Shelf life
D) Max. & Min. allowable temperature
E) Other instructions (e.g. requirements of stirring)
F) Dosage
Maximum and minimum to be specified as a percentage of

weight of cement.
Sub-Clause 1012.2 Add the following at the end
After selecting a few acceptable brands from MORT&H approved

list of manufacturers & types of admixture based on the
manufacturer’sdata / technical literature, independent acceptance
tests should becarried out for the same using the approved
combinations of cement /sand / aggregates intended for use in the
Project. After establishingthe basic acceptability using strength
criteria (compressive & tensilestrengths) a number of trial mixes be
designed using differentproportions of admixtures / cement / water
etc. to establish the databank on the behavior of the admixtures for
the project site conditions. A spectroscopic signature of accepted
product should be obtained andpreserved for comparison for
acceptance of the production lots.
Bidder 26 KDMC
and Drawings).
Retrials should be conducted with change in source / type of

cement.
WORKMANSHIP
The dosage should be finalized on the basis of field trial and
special mechanical devices should be used for dispensing the ad
mixture in the batching / mixing plant. No addition of admixture after
initial dosage is permitted (including addition in transit mixers).
Manufacturer’s experts should be available for consultation
/troubleshooting of problems associated with their product.
Theconditions of storage, shelf life etc. as specified by the
manufacturershould be strictly observed. The manufacturer’s
Quality AssurancePlan during process of production should be
obtained and filed forreference / record.
CLAUSE 1014 STORAGE OF MATERIALS Clause 1014.3 Aggregates

(Addition) The following shall be added to this Clause:
"A gregates shall be stored or stockpiled in such a manner that
segregation of fine and coarse sizes will be avoided and also that
the various sizes will not become intermixed before proportioning.
They shall be stored, stockpiled and handled in such a manner that
will prevent contamination by foreign materials."
CLAUSE 1015 TESTS AND STANDARDS OF ACCEPTANCE

Add the following as Para 3:
“Independent testing of pre-stressing strands shall be carried out by
the Contractor for each consignment from each source at site in the
laboratory approved by the Engineer in charge before use. The
tests shall be carried out for the properties as listed in clause 7.2.1
of BS-5896: 1980.These tests are in addition to the tests carried
out by the Manufacturer.”
SECTION 1100 PILE FOUNDATIONS CLAUSE 1101 DESCRIPTION

(Addition) Piling work shall be cast-in-situ bored piles of diameter as shown
on the drawing. Boring / drilling, socketing of piles shall bedone by
using hydraulically operated rotary drilling machines only.
M.S. Liner shall be provided to all piles of thickness as shownon

drawing and painted with coal tar epoxy paint on outer face i.e.face
in contact with earth.
Bidder 27 KDMC
and Drawings).
Sub-Clause 1101.2 Add the following at the end of clause 1101.2:
The Contractor shall submit information regarding proprietary

system of piling as per Clause 115.2.
The Contractor in his methods statement shall include the

procedure for carrying out initial and routine tests of piles including
design calculations and drawings. The format for reporting test
results shall be included inthe methods statement.
Sub-Clause 1101.4 Add the following as sub clause 1101.4
The scope of work shall comprise of the following:

a) Providing all materials including concrete, temporary and
permanent casing as required, labour and equipment
excluding reinforcing steelwhich shall be measured and
paid separately for installation of boredcast-in-situ piles.
b) Initial and routine testing of piles.
c) Integrity testing of piles as per provisions of bid documents.
d) Provision of access to movement of equipment, barricading
where necessary, pollution control measures including
measures tocontrol noise to minimum acceptable levels and
site clearance.
CLAUSE 1107 CAST IN-SITU CONCRETE PILES

Add the following at the end of para 1:
Where permanent steel liners/casing shown in the drawing, the
thickness of it shall be 6mm. Permanent casing shall be driven upto
the full depth of pile foundation or when rock stratum or hard/stiff
strata is encountered at mid depth, it shall be driven upto the
refusal subject to the approval of the Engineer in charge.
Temporary liners shall be provided in piles upto depth where sub

soil encountered during drilling is weak/ soft and may collapse
during the boring. The temporary liner shall be provided for a depth
of 2 m into non-collapsible stratum. Temporary liners shall be
withdrawn simultaneously as the concreting of the pile progresses
unless otherwise specified in drawing (IS: 2911-Part I-Section II).
Add the following after para 6:
Bidder 28 KDMC
and Drawings).
Bored cast in-situ piles shall be installed using hdraulic rotary rig of
appropriate capacity. The cutting edge shall be calyx of diamond
cutting edge as per the soil/rock condition. Drop chiseling in hard
rock may bepermitted in the special cases provided it does not
affect the adjacent structure adversely in any case.
Concreting of bored cast-in-situ piles shall be done by tremie

process.
In the exceptional case of interruption of concreting, which can be

resumed within 1 or 2 hours, the tremie pipe shall not be taken out
of the concrete. Instead, it shall be raised or lowered slowly, from
time to time. Concreting shall be resumed by introducing a little
richer concrete with as lump of about 200 mm.
If the concreting cannot be resumed before final set of concrete

already placed, pile shall be rejected.
The top of concrete in a pile shall be brought above the cut off level
to permit removal of all laitance and weak concrete before pile cap
is laid.
10% extra cement shall be added (in addition to cement

requirement as per design mix) for all underwater concreting.
Bidder 29 KDMC
and Drawings).
SECTION 1500 FORMWORK
CLAUSE 1503 DESIGN OF FORMWORK
Clause 1503.2 Add the following at the end of this Clause:
"For distribution of load and load transfer to the ground

throughstaging, an appropriately designed base plate must be
providedwhich shall rest on firm sub-stratum."
Clause
1514 SPECIAL ARCHITECTURAL FINISHES Materials add following
(Additiona clause
l Clause)
Where fecial architectural finishes have been specified which
require special patterns, grooves, ridges, surface finishes etc., andwhich
are to be obtained by casting concrete against forms, needspecially
designed forms and special finishing using suitablematerials. These forms
can be made from materials specified inIRC-87, relevant IS codes with
special workmanship/controls. Useof any other material is to be permitted
only after specific writtenapproval from the Engineer in charge.
Design and Workmanship, Removal, Protection and Reuse
The design and workmanship of these formwork has to be got approved

from the Engineer in charge. The method of removing formwork without
damaging the 'form finished' surface, use of de-bonding agents, the
protection and repair of forms and forms-surfaces, and limit on re-use etc.
are to be as per specification/drawings in absence of which the proposed
details are to be gotap roved from the Engineer in charge. All such
methods will have to be suitably improved based on the result of mock-up
or field use. The final procedure and details shall be improved till the
specified/desired architectural finish is obtained.
Mock-up
After design and before incorporation in the main work, the effectiveness
and success in achieving the desired finish has to be demonstrated /
confirmed by casting the mock-up. The approved 'mock-up' surface shall
be retained till the end of the project and then the 'mock-up' should be
dismantled/removed fromthe work site and disposed off as directed by the
Engineer in charge.
Bidder 30 KDMC
and Drawings).
Clause TOLERANCES
1515
(Addition All works shall be carried out true to the lines, levels and grades shown on
the
al Clause) drawings and within the tolerances specified below. The forms shall beso
designed and erected that the following tolerances are not exceeded
unless more stringent and specific specifications have been required by
the design and specified in the drawings/instructions. The contractor
shalestablish, erect and maintain in an undisturbed condition until final
completion and acceptance of the project, control points and bench
marksnecessary and adequate to establish these tolerances.
Sr Element Limits
no
1 For all elements, departure from established 10 mm
alignment
2 Departure from established grades 10 mm
3 Variation from level 10 mm in 3m. if exposed
20mm in 3m if backfilled
4 Variation from level or indicated grdae in slabs, 10 mm in 3m. if exposed
beams, horizontal and railing offsets 20mm in 3m if backfilled
5 Variation in cross sectional dimensions of -5mm, + 10mm
columns, piers, slabs, walls, beams and similar
Parts
6 Variation in slab thickness -5mm, + 10mm
7 Footings
8 Plan dimensions -15mm, + 30mm
9 Misplacement or eccentricity 2% of footing width in the
direction of displacement and
not exceeding 30mm
10 Reduction in thickness 5% of specified thickness
unless specified to be more
stringent.
11 Variations in size and locations of slab or wall 10 mm
openings
12 The Alignment Tolerances shall be as under
13 Tolerance in direction where ‘d’ is the dimension of
members
14 Member with a depth ± d/40
15 More than 200 mm 5 mm
Bidder 31 KDMC
and Drawings).
SECTION 1600 STEEL REINFORCEMENT

CLAUSE 1602 GENERAL
Paragraph 2 of Clause 1602 shall read as follows:

“Reinforcements shall be thermo mechanically treated (TMT)
deformed bars of grade Fe 500 conforming to IS: 1786.”.
CLAUSE 1604 BENDING OF REINFORCEMENT

Para 1 shall be read as follows:
The reinforcement shown on the drawings shall be considered
merely symbolic representations of the shape and position and
shall not be used by the Contractors to justify any deviation from
the stipulated requirements. Bar bending schedules and any
supplementary drawings as may be requiredshall be furnished by
the Contractor and got approved by the Engineer in chargebefore
start of work. The bending schedules shall state the number,
shapeand length of bar and weight in respect of each type. System
of bar referencing should be coherent and systematic. A separate
bar bending schedule shall be prepared for auxiliary bars like
spacers, chairs etc.
CLAUSE 1605 PLACING OF REINFORCEMENT
Paragraph (c) (i) of Clause 1605 shall be read as follows:
Cover blocks shall be made of concrete or cement mortar with the

same durability properties as the surrounding concrete and with the
same type ofconstituents. In visible surfaces, the cover blocks shall
be of the same colour and texture as the surrounding concrete. The
Contractor’s proposal forcover blocks shall be submitted to the
Engineer in charge for acceptance.
Add the following as sub Para (f) to this Clause:
Tolerances:
a) Tolerance of cover: Deviation shall not exceed + 10 mm No
negative tolerance is allowed.
b) Tolerance in position: Tolerance for deviation from the
positions shown in the drawings shall not exceed the
following:
Structural depth d (mm) Tolerance (mm)
Bidder 32 KDMC
and Drawings).
d < 1000 <10

<101000 < d < 2000 < 0.01d
2000 < d <20
CLAUSE 1606 BAR SPLICES
Sub-Clause 1606.1 First sentence of Clause 1606.1 shall read as follows:
To the extent possible, all reinforcement shall be furnished in full

lengths asindicated in drawings.
Add the following as paragraph 2 of Clause 1606.1:
The location of joints in continuous reinforcing bars, not shown in

drawings, shall be submitted to the Engineer in charge for
acceptance. If nothing contrary has been specified, the number of
bars to be joined in any cross-section shall notexceed one-third of
the total.
Sub-Clause 1606.2 Welding
Sub-Clause 1606.2.1 Add the following at the end of the paragraph:
“In prestressed concrete members, when welding of un
tensionedreinforcement is permitted by the Engineer in charge, it
shall be carried out beforeinsertion of the prestressing
tendons/sheathing.”
CLAUSE 1607 TESTING AND ACCEPTANCE
Add the following as the last paragraph of Clause 1607:
Manufacturer’s test certificate regarding compliance with Indian

Standards for each lot of steel shall be obtained and submitted to
the Engineer in charge. Ifrequired by the Engineer in charge, the
Contractor shall carry out confirmatory testsin the presence of a
person approved by the Engineer in charge. Cost of these
testsshall be borne by the Contractor. The sampling and testing
procedure shallbe as laid down in IS: 1786-1985. However, if any
test piece selected from a lot fials, no re-testing shall be done and
the lost straightway be rejected
SECTION 1700 STRUCTURAL CONCRETE
CLAUSE 1704 PROPORTIONING OF CONCRETE (Addition) Add the following at
the end of this clause:
“In proportioning concrete, the quantity of both cement and
aggregate shall be determined by weight. Where the weight of
Bidder 33 KDMC
and Drawings).
cement isdetermined by acceptin the manufacturer’s weight per

bag, a reasonable number of bags shall be weighed separately to
check the net weight. Where cement is weighed form bulk stock at
site andnot by bag, it shall be weighed separately from the
aggregates. Water shall either be measured by volume in
calibrated tanks or weighed. All measuring equipment shall be
maintained in a clean andserviceable condition. Their accuracy
shall be periodically checked. It is most important to keep the
specified water-cement ratio constantand at its correct value. To
this end, moisture content in both fine andcoarse aggregates shall
be determined as frequently as possible; frequency for a given job
being determined by the Engineer in chargeaccording to the
weather conditions. The amount of mixing watershall then be
adjusted to compensate for variations in the moisturecontent. The
determination of moisture content in the aggregates shallbe done
as per IS: 2386 (Part III). Suitable adjustments shall also bemade in
the weight of aggregates to allow for the variation in weightof
aggregates due to variation in their moisture content.”
Sub-Clause 1704.6 Add the following as clause 1704.6:
Materials for pumped concrete:
Materials for pumped concrete shall be batched consistently and
uniformly. Maximum size of aggregate shall not exceed one-third of
the internal diameter of the pipe.
Grading of aggregate shall be continuous and shall have sufficient
ultra fine materials (materials finer than 0.25 mm). Proportion of
fine aggregates passing through 0.25mm shall be between 15 and
30% and that passing through 0.125 mm sieve shall not be less
than 5% of the total volume of aggregate. Admixtures to increase
workability can be added. When pumping long distances and in hot
weather set-retarding admixtures can be used. Fluid mixes can be
pumped satisfactorily after adding plasticizers and super
plasticizers. Suitability of such concrete shall be verified by trial
mixes and by performing pumping test.
CLAUSE 1705 ADMIXTURES
(Addition) Add following at the end of this clause
“Duly tested admixtures/additives conforming to IS: 6925 and IS:
9103 (without replacement of cement) may be used subject to
satisfactory proven use, with the approval of the Engineer in
charge. Admixtures generating Hydrogen or Nitrogen and
containing chlorides, nitrates, sulphides, sulphates and any other
material liable to affect the steel or concrete shall not be permitted.
The general requirements, physical and chemical requirements
shall be as per Clause 1012.
Bidder 34 KDMC
and Drawings).
Admixtures s h a l l be proc u re d only from manufacturers

approved by MORT&H”.
CLAUSE 1707 EQUIPMENT
Para 1 of this Clause shall read as under:
“Unless specified otherwise, equipment for production,
transportation and compaction of concrete shall be as under:
 For production of concrete: Batching and mixing of the concrete
shall be done in a concrete batching and mixing plant fully
automatic of a minimum capacity of 40 cum/hour. The plant
shall be approved by the Engineer in charge.”
Paragraph 3 of this clause shall read as follows:
“The accuracy of measuring devices shall fall within the following
limits:
Measurement of Cement ±1% of the quantity of cement in each
batch.
Measurement of Water ± 1% of the quantity of water in each
batch.
Measurement of Aggregate ± 2% of the quantity of Aggregate in
each batch.
Measurement of ± 1% of the quantity of Admixture in
Admixture batch
Paragraph 3(b) & 3(c) shall remain unchanged.
Add the following paragraph at the end of the clause:
Batching, mixing transportation and placing concrete.
Once the concreting of a section is started, it has to be completed
as a continuous operation. Before starting an important placement,
the Contractor shall submit to the Engineer in charge an equipment
list to ensure that sufficient equipment is available for batching,
mixing, transporting and placing concrete and once the concreting
of a section is started, it can be completed as a continuous
operation within a reasonable time.
CLAUSE 1708 BATCHING, MIXING, TRANSPORTING, PLACING AND
COMPACTION
Add the following paragraph at the end of the clause:
For Placing Concrete with Pumps: Pipe Lines from the pump to the
pacing area should be laid out with a minimum of bends. For large
concrete placements standby pumps shall be available. Suitable
valves (air releasevalves shutoff, valves etc.) shall be provided as
per the site needs. Theum ing of concrete shall be preceded by a
priming mix to lubricate the pump and pipeline. A rich mix of
creamy consistency shall be required forlubricating the pipelines;
Bidder 35 KDMC
and Drawings).
continuous pumping shall be done to the extentpossible. After

concrete has been placed the lines all related equipment shallbe
cleaned immediately. A plug sponge ball shall be inserted in the
end nearthe pump and shall be forced through the line by either
water or airpressure. Pipes for pumping should not be made from
materials, which canharm concrete; aluminium alloy pipelines shall
not be used.
CLAUSE 1709 CONSTRUCTION JOINT (Refer Appendix 1700/1, Preparation
of the Surface of the Joint)
In the2nd paragraph under the heading “Preparation of the Surface
of the Joint”, add after the words “the surface shall be roughened”
the words “thecoarse aggregate shall be made visible to a depth of
5 mm to 10 mm”.
In the third paragraph under the heading “Preparation of the
Surface of the Joint” add the following at the end of paragraph.
“Bush hammering is not permitted since it loosens the coarse
aggregate and results in extensive micro cracks.”
Concreting of Joints:
Under the heading “Concreting of Joints”, add the following at the
end of sub-Para 3”.
“At vertical construction joints, a fine mesh on the inner surface of

the stopping board shall be placed, if directed by the Engineer in
charge, the facilitate removal of laitance.”
CLAUSE 1711 CONCRETING IN EXTREME WEATHER

Sub -Clause 1711.2 Hot Weather Conditions
Add the following at the end of paragraph 1 of the above clause:
Where the Contractor proposes to use ice to cool the concrete or

mixing water or any of the ingredients, the Contractor shall provide
a refrigeration plant to avoid use of contaminated ice.
Placement of concrete shall not be permitted when day

temperature exceeds 40oC.
CLAUSE 1712 PROTECTION AND CURING

Sub-Clause 1712.2 Water Curing
Add the following at the end of Para 1:
Bidder 36 KDMC
and Drawings).
Water sprinklers or perforated pipes shall be used for curing of

concrete for all major bridges, ROB’s and grade separators. Such
arrangement must be inplace & tested before concreting for its
proper functioning and shall bemaintained for a minimum period of
14 days after concreting.
Approved concrete curing compounds should be preferred where
water curing cannot be done reliably.
Section PRESTRESSING Description
1800
Add the following after first paragraph of section 1801
1801 1801.1 The work specified in this Section shall also consist of
furnishing, installing, stressing and grouting prestressing strand and
HS Bars in accordance with the drawins and the requirements of
these specifications or as approved by the Engineer in charge.
It shall also include the furnishing and installing of any

appurtenant items necessary for the particular prestressing system
used, including but not limited to anchorage assemblies, additional
reinforcing bars required to resist stresses caused by anchorage
assemblies, ducts, vents, inlets, outlets and grout used for pressure
grouting ducts
1801.2 Contractor Proposed Options

The Contractor may purpose for consideration by the Engineer in
charge certain variations from the prestressing systems shown in
the contract 1801.3 document.
1801.3 Restrictions to Contractor Proposed Options
Materials and devices used in the prestress system shall conform

to the requirements of the following Materials Section of this
Specification. The not compressive stress in the concrete after all
losses is at least as large as that provided by system shown on the
plans. The distribution of individual tendons at each section
generally conforms to the distribution as shown on the plans. The
ultimate strength of the structure with the proposed prestressing
system meets the requirements of IRC-18.
Stresses in the concrete and prestressing steel at all sections and
all stages of construction meet the requirements of the Design
Criteria noted on the plans.
Bidder 37 KDMC
and Drawings).
Compliance with all provisions of the Design Criteria, as noted on

the plans.
The Contractor fully redesigns and details, as required, the

elements where the alternate prestressing system is proposed to
be used. The Contractor submits complete shop drawings including
the prestressing scheme and system, reinforcing steel, and
concrete cover, and design calculations (including short- and long-
term Prestress losses) for the Engineer in charge’s approval.
15.2mm diameter strand and 12.7mm diameter strand may be
substituted for each other on an equal force basis within any
tendonsize shown by the designer.
1801.4 Shop Drawings
The Contractor shall submit detailed shop drawings, which include, but are not
limited to:
1) A complete description of and details covering, each of the prestressing systems
to be used for permanent and temporary tendons. This shall include:
a) Designation of the specific prestressing steel, anchorage devices, bar couplers,
duct material and accessory items.
b) Properties of each of the components of the prestressing system.
c) Details covering assembly of each type of prestressing tendon.
d) Equipment to be used in the restressing sequence.
e) Procedure and sequence of operations for prestressing and securing tendons
f) Procedure for releasing the prestressing steel elements
g) Parameters to be used to calculate the typical tendon force such as,
expectedfriction coefficients, anchor set and prestress steel relaxation curves.
2) A table detailed the prestressing jacking sequence, jacking forces and initial
elongations of each tendon at each stage of erection for all prestressing
3) Complete details of the anchorage system for prestressing including certified
copies of the reports covering tests performed on Prestress anchorage devices as
required in the following Materials Section D, and details for any reinforcing steel
needed due to stresses imposed in the concrete by anchorage plates
4) For the operation of grouting prestressing tendons; the materials and proportions
for grout, details of equipment for mixing and placing grout and methods of mixing
and placing grout.
5) Calculations to substantiate the prestressing system and procedures to be used
including stress-strain curves typical of the prestressing steel to be furnished,
required jacking forces, elongation of tendons during tensioning, and seating
losses. These calculations shall show a typical tendon force after applying the
expected friction coefficient, and anticipated losses including anchor set losses.
Elongation calculations shall be revised when necessary, to properly reflect the
Bidder 38 KDMC
and Drawings).
modulus of elasticity of the tendon material as determined from in place friction

tests in accordance with Section 5.7, Division II, AASHTO Guide Specifications for
Design and Construction of Segmental Concrete Bridges.
6) Complete details of the apparatus and method to be used by the Contractor for
the test.
CLAUSE 1804 TESTING OF PRESTRESSING STEEL AND ANCHORAGE
Add following Paragraphs to the section.
All samples shall be representative of the lot and in the case of wire
or strand shall be taken from the same master roll. At least 5.0m
length shall be selected from each lot for testing. Also two
anchorage assemblies, complete with distribution plates of each
size or types to be used, shall be tested. Testing of anchorage -
cable assemblies shall be carried out in accordance with
procedures in FIP document "Recommendations for the
acceptance of Post Tensioning systems”, June 1993.
The frequency of such tests should be as follows:
 For acceptance of the tendon at the stage of submission of
tendons, the manufacturers certificate together with the data of
previously conducted and most recent test results of
"Acceptance Testing" is acceptable subject to further testing as
given below.
 Acceptance Testing for the works
a) Static load test for tendon-anchorage assembly
 A series of three tests using the proposed combination of
anchorage systems and the prestressing strand/wire/bars. All
the tests should meet the following requirements.
 Residual deformations of anchorage components after the test
should confirm the reliability of the anchorage.
 The increase in the displacements between the anchorage
components as well as between the prestressing steel and
anchorage components should not be disproportionate to the
increase in tendon force.
 The above relative displacements during the 0.8Fpk load stage
should stabilize within the first thirty minutes of the load
duration of 1 hour.
 The mode of failure of tendon should be by the fracture of the
prestressing steel. Failure of the tendon should not be induced
by the failure of anchorage components.
 The measured anchorage efficiency should be:
(Refer CEB/FIP Guidelines for details).
Bidder 39 KDMC
and Drawings).
 The total elongation eu in free length of the tendon under the

load Ftu should be eu > 2%
b) Dynamic load test with tendon/ anchorage assembly
This test is to be carried out for every new combination of type of

anchorage and tendons. A series of three successful tests shall becarried
out for acceptance of the systems. This test is consideredas essential for
both unbonded and bonded cables as per FIPdocument.
Requirements:
Each test result should meet the following requirements

 Fatigue failure of anchorage components should not occur.
 The minimum fatigue strength of post-tensioning system
shouldbe. sp min = 80 MPa
 The fatigue strength is defined as the stress range (.sp), which
is endured for 2 million cycles without failure of more than 5%
of the initial cross-section of the tested tendon at beginning of
the test.
Clause WORKMANSHIP
1805 Add following after second paragraph of 1805.1 Protection of
Prestressing Steel
Replace the entire Section with the following:
All prestressing steel shall be protected against physical damage at

all times from manufacture to grouting or encasing in concrete.
Prestressing steel that has sustained physical damage at any time
shall be rejected. Any reel that is found to contain broken wires
shall be rejected and the reel replaced.
Prestressing steel shall be packaged in containers or shipping

forms for protection of the steel against physical damage and
corrosionduring shipping and storage. A corrosion inhibitor, which
preventsrust or other results or corrosion, shall be placed in the
package orform, or shall be incorporated in a corrosion inhibitor
carrier typepackaging material, or
when permitted by the Engineer in charge, a corrosion inhibitor

may be applied directly to the steel. The corrosion inhibitor shall
have no deleterious effect on the steel or concrete or bond strength
Bidder 40 KDMC
and Drawings).
of steel to concrete. Inhibitor carrier type packaging material shall

conform to the provisions of U.S Federal Specifications MIL-P3420.
Packaging or forms damaged from any cause shall beimmediately
replaced or restored to original condition.
The prestressing steel shall be stored in a manner which will at

alltimes prevent the packing material from becoming saturated
withwater and allow a free flow of air around the packages. Ifthe
useful life of the corrosion inhibitor in the package expires, itshall
immediately be rejuvenated or replaced.
At the time the prestressing steel is installed in the work, it shall

befree from loose rust, loose mill scale, dirt, paint, oil, grease or
otherdeleterious material. Removal of tightly adhering rust or mill
scalewill not be required. Prestressing steel which has
experiencedrusting to the extent that it exhibits pits visible to the
naked eye shallnot be used in the work.
The shipping package or form shall be clearly marked with theheat
number and with a statement that the package contains high-
strength prestressing steel and care is to be used in handling.
The type and amount of corrosion inhibitor used, the date when
placed, safety orders and instructions for use shall also be marked
on the package or form.
If the period of time between installation of prestressing steel and

grouting of the tendon will exceed 10 calendar days, the
prestressingsteel shall be protected from corrosion during the entire
period it isin place but ungrouted as provided below:
When the plans provide for prestressing steel to be installed inone

unit with a length of prestressing steel left projecting to bethreaded
into another until during erection, all of the prestressingshall be
protected from corrosion from immediately after it isinstalled in the
first unit until the tendon is grouted in the secondunit as provided
below:
When corrosion protection of in-place prestressing steel is required,

a corrosion inhibitor which prevents rust or other resultsof corrosion
shall be applied directly to the prestressing steel. T ecorrosion
inhibitor shall have no deleterious effect on the prestressing steel or
grout or bonding of the prestressing steel tothe grout. The inhibitor
Bidder 41 KDMC
and Drawings).
shall be water soluble. The corrosioninhibitor, the amount and time

of initial application and the frequency of reapplication shall be
subject to the Engineer in charge’s approval.
CLAUSE 1807 TENSIONING EQUIPMENT
Add the following at the end of Para 2:

“Jack and Pump shall be calibrated by an approved laboratory prior
to use and then at intervals not exceeding three months.
A standby set of jack, pumps and pressure gauges shall always be
available at site where prestressing is in progress.”
CLAUSE 1808 POST TENSIONING
Add the following at the end of Para 5 of this clause:
“Parallel measurement by load cell in combination with direct
readingof Pressure gauge shall be preferred. In any case such
parallel measurements by load cell shall be made for at least 10%
of the cables stressed during any tensioning operation.”
Add the following at the end of this Clause:
“The Contractor shall submit fabrication drawings, detailing

prestressing cables, anchorages, couplers, chairs and supports,
templates or forms holding anchorage assemblies etc. for Engineer
in charge's approval at least one month before commencement of
work insuperstructure. Stressing schedules shall be prepared by
the Contractorand submitted to Engineer in charge for approval.”
CLAUSE 1809 GROUTING OF PRE-STRESSED TENDONS

Add new Para at the end of Clause as under:
“Where directed by the Engineer in charge the Contractor shall
perform full-scale site test to determine the adequacy of grout mix,
equipment andgroutin method. The Contractor shall submit a
method statement detailing the test procedure.
Special Attention is directed to Appendix 1800 / III of the Standard
Specifications. Contractor shall arrange for testing of all
groutcomponents and of the mix, prior to the start of grouting and
wheneverthe source of any component is changed, to ensure that
the grout is freeof anything that could promote shrinkage or
cracking of the grout orcorrosion in the tendons. Further samples of
grout and its components shall are obtained for each day of
grouting at each site where grouting iscarried out and a full
chemical analysis shall be performed on thesamples.”
Bidder 42 KDMC
and Drawings).
CLAUSE 1819 JOINTS IN CONSTRUCTION WITH PRE-CAST UNIT

Add new clause:
“Joints between a series of precast concrete units which are to be
prestressed together by post-tensioning shall be such as to ensure
eventransfer of compression from one unit to another.
Whatever be the method of jointing, the holes of the prestressing
steel shall be accurately made and shall meet one another in true
alignmentat ends. Jigs shall always be used. Care shall be taken to
ensure that thejointing material does not enter the duct or press the
sheath against the prestressing steel.
Jointing by application of mortar on the face of a unit and then
placing another unit against it shall not be permitted.
Suitability and effectiveness of the method should be got confirmed

from a suitably designed mock-up.”
SECTION 2000 BEARINGS

CLAUSE 2001 DESCRIPTION
Add the following as paragraph 2 of this clause:
“Within 90 days of award, the Contractor shall submit detailed

specifications, designs and drawings including installation drawings
and maintenance manual, for the approval of the Engineer in
charge. Designs shall also include review and modifications of
designs and drawings of bearing pedestals and other elements
required for installation. The installation of bearings shall be carried
out under the supervision of the manufacturer of the bearings. The
Contractor shall provide the bearings only from the manufacturers
approved and enlisted by the Ministry of Road Transport &
Highway. In addition to routine testing of the materials and bearings
at manufactures premises, the Contractor shall arrange at his own
cost testing of random samples of 1 %(Minimum 1 no. of each type)
of bearings from independent agencies, other than manufactures’
own facilities, duly approved by the Engineer in charge.The
bearings shall be selected by the Engineer in charge / his
authorised representative and duly sealed in his presence for
dispatch to the independent agency.”
CLAUSE 2005 ELASTOMERIC BEARINGS

Sub-Clause 2005.4 Acceptance Specifications
Bidder 43 KDMC
and Drawings).
In Para 5, substitute the words "Engineer in charge or his

authorised representative" for the word "Inspector".
Sub-Clause 2005.4.5 Inspection Certificate
Substitute the words "Engineer in charge or his authorised
representative" for the word "Inspector".
Sub-Clause 2005.4.6 Quality Control Certificate
Delete the word “/Inspector” in the 3rd line of sub para b) in 1st
paragraph.
CLAUSE 2006 POT BEARINGS
The clause shall read follows:
“Pot Bearings shall conform to the requirements of IRC: 83 (Part III)

2002.”
Sub-Clause 2006.1 General
Sub-Clause 2006.1.2 Add after 2nd sentence “Provisions of IRC83 (Part III) shall be
applicable for POT, POT cum PTFE, PIN and Metallic Guide
Bearings”
CLAUSE 2011 ADD new clause as under:

“Tar Paper bearing shall be reinforced bitumen laminated Kraft
paper conforming to IS-1398”.
SECTION 2100 OPEN FOUNDATI0NS
Sub-Clause 2103 GENERAL
Add the following as sub para (ix):
Confirmatory borehole, Foot and Plate load tests and Electrical
Resistivity tests at proposed foundation location.
Clause 2106 TOLERANCES

Reference to Tolerance shall be made to Clause 1715.
SECTION 2200 SUB-STRUCTURE

CLAUSE 2204 PIERS AND ABUTMENTS
Add the following paragraph at the end of clause:
“Wherever necessary, suitable cofferdams or other means shall be
provided to exclude water from the construction area. The
Contractor shall provide necessary pumping equipment for
dewatering areas”.
Bidder 44 KDMC
and Drawings).
SECTION 2300 CONCRETE SUPER-STRUCTURE

Clause 2305 PRESTRESSED CONCRETE CONSTRUCTION
Sub-Clause 2305.2 Box Girder
Add the following at the end of para 1:
“Contractor shall, in his methods statement, indicate the location of

construction joints for the Engineer in charge’s approval.”
Add new sub clause 2305.5 as under:
Sub-Clause 2305.5 PSC Solid Slab
Casting of the slab shall be done in a single stage without

construction joints.
The portions of deck near expansion joints shall be cast along with
Reinforcements and embedments for expansion joints.
The deck slab shall be finished rough, but true to lines and levels
as shown in drawings. Bearings shall be set as shown in drawings.
SECTION 2500 RIVER TRAINING AND PROTECTION WORK
CLAUSE 2504 PITCHING/REVETMENT ON SLOPES

The title of this Clause shall read as under:
“PITCHING/REVETMENT ON SLOPES & FILTER MEDIA”
Sub-Clause 2504.2.2 Filter Medium

Add after 1st Para:
“The material for filter media behind abutment shall conform to
general guide lines given in Appendix 6 of IRC-78 (Standard
Specification and Code of Practice for Road Bridges – Section-
VII).”
Section 2600 EXPANSION JOINTS

Clause 2602 GENERAL
The following sub-clauses 2602.5 & 2602.6 shall be added after
subclause 2602.4.
Bidder 45 KDMC
and Drawings).
Sub-Clause 2602.5: Asphaltic lug joint, Modular Strip seal and

Compression seal joint shall be as per the requirements of IRC: SP
69 –2005. For materials, installation, and testing and acceptance
standardsstipulations of IRC: SP 69 – 2005 shall be followed.
Sub-Clause 2602.6: For all expansion joints which are
proprietary, minimum guarantee of 10 years for their satisfactory
performance shallbe given by the contractor.
CLAUSE 2703 RAILING AND CRASH BARRIER
Sub-Clause 2703.3 Cast-in-Situ Railing / Crash Barrier
Add new sentence after the last sentence of para 3 as following.
“Location of construction joints shall be determined in advance and
approved by the Engineer in charge.”
Add the following additional clauses:

Sub-Clause 2703.5 Concrete Crash Barrier for Bridges
Sub-Clause 2703.5.1 General
This work shall consist of construction; provision and installation of
concrete crash barrier on the bridge deck / approach slab /
approaches at locations and of dimensions as shown on the
drawings or as directedby the Engineer in charge.
Sub-Clause 2703.5.2 Materials

All materials shall conform to Section 1000-Materials for Structures
as applicable, and relevant Clauses in Section 1600 shall govern
the steelreinforcement. The concrete barriers shall be constructed
either by the“cast-in-place with fixed forms” method or the
“extrusion or slip form”method or a combination thereof at the
Contractor’s option with theapproval of the Engineer in charge.
Where “extrusion or slip form” method isadopted, full details of the
method and literature shall be furnished.
An expansion joint with Polysulphide Joint sealants and bituminous

fiber board shall be provided in the crash barriers at the location of
expansion joints/gaps on the bridge, approaches etc.
Sub-Clause 2703.5.3 Construction Operations

The location of crash barrier shall be strictly adhered to as shown
on the drawing and as directed by the Engineer in charge.
Concrete crash barriers shall present a smooth, uniform
appearance in their final position, conforming to the horizontal and
Bidder 46 KDMC
and Drawings).
vertical lines shown on the plans or as ordered by the Engineer in

charge and shall be free of lumps, sags or other irregularities. The
top and exposed faces of the barriers shall conform to the specified
tolerances, as defined in Clause 809.4, when tested with 3 m
straight edge, laid on the surface.
The concrete crash barrier or precast shall be given two coats of

cement paint or aqua based paint as directed by the Engineer in
charge ofapproved brand and shade.”
Sub-Clause 2703.5.4 Tolerance
The overall horizontal alignment of crash barrier and rails shall not
depart from the road alignment by more than + 30 mm, nor deviate
in any two successive lengths from straight by more than 6 mm and
the faces shall not vary more than 12 mm from the edge of a 3 m
straight edge. Barriers shall be at the specified height as shown in
the plans above the edge of the nearest adjacent carriageway or
shoulder, within a tolerance of + 30 mm.
Sub-Clause 2703.6 POLYSULPHIDE RUBBER JOINT SEALANT
Polysulphide Joint sealants with bituminous fiberboard shall be
provided in the Expansion Joints/ gaps in Crash Barriers.
Before application it shall be ensured that the top of the bituminous
fiber board and the concrete faces are dry, sound, free from dirt,
grease and other loose foreign matter. A thin coat of primer shall be
applied on concrete faces with a brush to air dry before applying
sealant. The components of the sealant i.e. base and hardener
shall be mixed in a slow speed mixed sealant till uniform color is
obtained. Placement of the mechanical mixer shall be done with
either cartridge or fully enclosed gun barrels within 30 minute of
mixing. Manufacturer’s recommendation shall be followed.
The sealing compound shall be two packs, low modulus of elasticity
Polysulphide elastomer having bituminous ingredients such as Cico
T-680 or equivalent with following properties of the cured
compound. Tensile strength - 0.4 MPa . 10%
Modulus of elasticity - At 100% elongation: 0.15 MPa
Elongation - Elongation at break 550%
Hardness Shore ‘A’ hardness 22 . 3 @
25°C
Operating temperature - - 20°C to + 80°C
Shrinkage - Less than 1%
Permanent dynamic - ±25%
Movement capability
Bidder 47 KDMC
and Drawings).
Polysulphide material shall be approved by the Engineer in charge

prior to procurement.
CLAUSE 2704 APPROACH SLAB

Add new paragraph after para 3 as under:
Provision of approach slab shall be in accordance with “Guidelines

regarding Approach Slab for Bridges” given in MOST circular no.
RW/NH34015/2/86-S&R dated 22 June 1994.
CLAUSE 2833 STONE PITCHING 300MM THICK ON SLOPES GROUTED WITH
1:3
CEMENT MORTAR
Slope protection with stone pitching shall be provided at abutments.
The work shall be executed in accordance with Specifications,
Section2500.
CLAUSE 2834 PROVIDING AND PLACING IN POSITION MECHANICALLY
FABRICATED GABION WALL AROUND ABUTMENT AND
PIERS INCLUDING EXCAVATION AND BACK FILLING
The work shall be executed in accordance with Specifications

Section 2500 clause 2503. Excavation and back filling shall be
done inaccordance with Specifications Section 300.
Gabions shall consist of a double twisted Zinc & PVC coated wire
mesh container of variable sizes, uniformly partitioned into internal
cells, interconnected with other similar units, and filled with stone at
the siteto form flexible permeable, monolithic structures.
Mechanically fabricated double twisted hexagonal mesh type
gabion conforming toASTM/ BS specifications shall be used.
Mechanically fabricated double twisted hexagonal mesh shall be

approved by the Engineer in charge prior to procurement and use.
PART C ADDITIONAL TECHNICAL SPECIFICATIONS
CLAUSE SP-1 PLANT AND EQUIPMENT FOR AGGREGATES AND

CONCRETE
1 AGGREGATE PROCESSING PLANT
Aggregate processing plant to be provided by the Contractor shall
conform to the following:
Bidder 48 KDMC
and Drawings).
1.1 Type of Plant

Except where aggregates are supplied from commercial sources, a
modern and dependable aggregate plant capable ofproducing
satisfactory concrete aggregates in sufficient quantities and the
ratenecessary to met the requirements of the construction
scheduleshall be provided at a location acceptable to the Engineer
in charge. Completefacilities shall be provided for proper crushing,
washing, classifying, storing, reclaiming and delivering the
aggregates to the mixing plant.
1.2 Samples and Test

The aggregate plant shall be operated for a sufficient time
inadvance of the dates set for first placement of concrete to
permitthe development of procedures which result in high
capacityproduction of aggregates proven by tests to meet all
therequirements of this specification.
1.3 Fines in Sand

The facilitation for fine aggregate production shall be so
designedand operated as to retain the necessary quantity of
finerfractions. An excess of fines will not be permitted. If natural
sand isfrom marine source, the sand shall be cleaned of clayey
materialand washed with potable water before use. All crushing,
washing, screening, classifying, blending, batching, or other
properties of fine aggregate necessary to meet these specifications
shall beperformed so as to produce acceptable gradation
complying withthis specification.
1.4 Drainage of Sand
Aggregates shall not be removed directly from the washing or
classifying operations to the aggregate bins in the concrete mixing
plant, but shall be stored as required, to permit drainage of excess
water and in such a manner as to avoid contamination by foreign
materials. Sand shall remain free-draining storage for atleast 48
hours prior to use.
1.5 Segregation
The stock piles for aggregates shall be formed so as to prevent
segregation, and as approved by the Engineer in charge. The
deposition and removal there from shall be done in a manner to
maintain the uniformity of grading. The side slopes of stock piled
Bidder 49 KDMC
and Drawings).
aggregates shall be kept flatter than the angle of repose to prevent

accumulation of coarser material at the bottom of the slope.
1.6 Volume of Storage

Sufficient live storage of all size fractions of processed aggregates,
shall be maintained at all times, to permit continuous placing of
concrete at the rates so as to meet the Schedule requirements. If
aggregates are stock piled on theround, the bottom portion of the
stock pile within 30 cm of ground shall not be used. The Contractor
may also plan to store sufficient quantity of course and fine
aggregate so that concretingduring monsoon can proceed without
hindrance as the collectionof the same during monsoon may be
difficult.
1.7 Approval of Aggregate Plant Layout

Plans and written specifications for the aggregate processing plant
including description and capacity data on the processing
equipment, and flow charts of the whole processing operation
whichshall show rates of flow of material at the various crushing
and separation points in the processing, as well as the volumes of
thestock piles and the number and types of equipment to be used
intransporting the aggregates from aggregate plant to the
mixingplant shall be submitted to the Engineer in charge in
advance of plant erection for his approval.
2 CONCRETE PLANT
A modern dependable batch type mixing plant capable of producing

concrete of specified quality and at the rate of output required to
meet the schedule requirements, and a balanced complement of
transporting, handling and lacing equipment shall be provided at
locations and in a manner approved by the Engineer in charge. The
concrete mixing plant shall be completely installed for a sufficient
length oftime prior to scheduled date for placement of first concrete,
to enable the Engineer in charge to make the necessary physical
tests prior touse of the plant for the production of concrete.
Bidder 50 KDMC
and Drawings).
2.1 Standby Arrangement

As a standby arrangement to the batching and mixing plant the
stationary mixer / mixers of capacity 700 litres of mixed
concreteand other appropriate equipment shall be provided.
2.2 Type of Plant
The type of plant to be furnished shall be fully automatic. The term
“automatic” is used to define a plant in which: i) Batchweights are
set manually on a mix selector ii) Mixes are chargedautomatically
by mix selector iii) Materials are batched automaticallyIce flaking
machine of sufficient capacity shall be installed as a part of
batching plant.
2.3 Batchers
Individual weigh batchers shall be provided for all works,
requiringthe use of more than two separate size groups of coarse
ag regates. Cumulative weight batchers may be used for work
requiring the useof not more than two separate size groups of
coarse aggregates provided the cement is weighed and batched
separately from the aggregates. The batchers shall be arranged to
permit the convenient addition or removal of material. Batching
equipment shall be so constructed and arranged
that the sequence and time of discharge can be controlled
to produce a reblending and mixing of the ag regates and,
wherever possible, mixing of the cement with the aggregates as the
materials pass through the charging hopper in to the mixer. This
control shallbe affected by the controls of the batcher discharge
gates. Batchercontrols shall be so interlocked that a new batching
cycle cannotbe started until all batchers are completely empty.
(i) Weighing Units

Every delivering point of aggregates and cement in to the mixer,
charging hopper shall have a weighing unit and each weighingunit
shall include a visible, springless direct reading dial whichshall
indicate the scale load at all stages of the weighing operationfrom
zero to full capacity. The scale dials and the weighingequipment
shall be in full view of the operator, so that he mayconveniently
observe the operation of the batcher gates and thedischarge of the
materials. Provision shall be made for adjustmentand change in
weights of materials being charged in the hopper.
Bidder 51 KDMC
and Drawings).
(ii) Measuring Water & Ice

Water shall be measured by weight except in situations forwhich
written approval is given by the Engineer in charge to measure
byvolume. The mechanism for measuring and delivering water to
themixers shall not permit leakage when the valves are closed. Ice
shallbe measured by weight. The filling and discharge shall be
measuredby weight. The filling be capable of ready adjustment to
permitvarying the quantity of the admixtures to be batched.
Theequipment shall be kept in a clean and fully operating condition.
(iii) Tolerance in Batching, Weighment Errors
Weighing devices shall be capable of measuring the various

ingredients of the following accuracy.
Materials Percent
Cement 1 (by weight) water
Aggregate smaller than 40 mm size 2 (By weight) water
Admixture 2 (By weight or volume)
iv) Records & Charts

An accurate record shall be maintained at the batching plant by the
contractor for the followings:
a) The weight of the cement, water and admixture.

b) The weight of the aggregate for each size shall be recorded
separately.
c) Temperature of the concrete immediately after mixing.
d) Mixing time of each batch when all the materials are loaded
into the mixer. Time when the concrete is delivered from
the mixer.
f) Ambient temperature.
v) Recorder Records & Charts
A recorder shall be provided for each set of units measuring each

ofthe materials delivered to the mixer. The recorder shallproduce a
continuous visible record, on a single ruled chart, of theweight of
the cement, water and each size of aggregates, of themixing time
of each batch after all materials are in the mixer, of thetemperature
of the concrete and of the time of day at intervals of notmore than
Bidder 52 KDMC
and Drawings).
fifteen (15) minutes. The recorder shall be completelyhoused and

shall be capable of being locked and shall be placed in aposition
convenient for observation by the plant operator and theEngineer in
charge. Each chart shall be so ruled and printed that it may
bereadily and permanently identified, so that the quantities and
timemay be read directly without scaling or calculation. A portion of
therecorder chart equivalent to at least thirty (30) minutes of
plantoperation shall be visible after recording. This portion of the
chartshall be supported over its entire width on a smooth,
firmbacking so that notes can be made without puncturing the
paper.
The recorders and scale dials shall be housed in a room, box or
compartment visible at all times and sufficiently tight to exclude
objectionable dust coming from the plant operation.
vi) Cement Weight Recorder
This shall be provided separate from and in addition to the

autographic recorder chart, an automatically printed record ofthe
quantity of cement discharged from the batobers for eachbatch of
concrete. The weight of the cement charged shall berecorded in
kilograms, the recording shall be continuous and eachbatch shall
be recorded separately. The interconnecting mechanism from the
batcher to the recorder shall be lockedand the key thereafter turned
over to the Engineer in charge.
vii) Air Temperature Recorder
There shall be provided on autographic record of the

airtemperature. The thermometer shall be placed at location so as
totruly represent the outside air temperature at the site.
Therecorder itself shall be properly housed.
2.4 Mixers may be stationery mixers of either the tilting or non-tilting

type of approved design.
i) Maintenance
The mixers shall be maintained in satisfactory operating condition,

and mixer drums shall be kept free of hardened concrete.
Mixerblades shall be replaced when worn down more than 10
percent oftheir depth. Should any mixer at any time
Bidder 53 KDMC
and Drawings).
produceunsatisfactory results, leak mortar or cause wastage of

materials, its use shall be promptly discontinued until it is repaired.
ii) Mixing Time

The mixing periods specified herein are to ensure proper
quality control. The mixing time will be increased when such
increase is necessary to secure the required uniformity and
consistency of the concrete. Excessive over mixing requiring
additions of water will notbe permitted. When stationary mixers are
used, the mixing time for each batch shall be as follows;
Time shall start when all solid materials are in the mixer
drum,provided that all of the mixing water shall be introduced
before one-fourthof the mixing time has elapsed. The Engineer in
charge, may, however, direct change in mixing time, if he, in his
opinion, considers such change necessary.
Capacity of Mixer (Cubic Metre) Time of Mixing (Min.)
Upto 2.00 Cubic Metre 1 ½ Upto 3.00
Cubic Metre 2
Upto 4.00 Cubic Metre 2½
Stationary mixers shall be provided with an acceptable device to

lock the discharge mechanism until the required mixing time has
elapsed. Provision also shall be made to assure that each batch is
discharged completely beforethe mixer is recharged.
2.5 Provision for Inspection

The complete plant assembly shall include provisions to facilitate
the inspection of all operations at all times.
2.6 Maintenance of Records

All records and charts of the batching and mixing operations shall
be prepared as specified herein and promptly turned over to the
Engineer in charge.
2.7 Sampling Facilities

Suitable facilities shall be provided for readily obtaining
representative samples of aggregate from each of the batchers,
and suitable devices for obtaining representative samples of
concrete for slump tests, unit weight, air content, and uniformity
tests to be madeby the Engineer in charge, shall be provided. All
Bidder 54 KDMC
and Drawings).
necessary platforms, tools and equipment for obtaining samples

shall be furnished at the start ofwork.
2.8 Concrete Specimens

Concrete specimens will be prepared from the mixes used in
thework and tested to determine the adequacy of control of
thematerials entering into the concrete mix. Preparation, storage
andtesting of the specimens will be performed by the Engineer in
charge. Suitablefacilities when demanded shall be provided within
the plant for theEngineer in charge and his assistants to carry out
the necessary control work.
2.9 Test Weights

Standard test weights and any other auxiliary equipment
requiredfor checking the operating performance of each scale or
other measuring device shall be provided. Periodic tests shall be
made inthe presence of the Engineer in charge in such a manner
and at such intervalsas may be directed by the Engineer in charge.
Upon completion of eachsuch test, and before further use of the
measuring, weighing orrecording devices, such adjustments,
repairs, or replacements shallbe made as may be required to
secure satisfactory performance.
2.10 Approval of Concrete Plant Layout

Plans and Technical data for the concrete plant proposed for use to
produce the quantities and quality of concrete for completion of the
concrete works under this specification shall be submitted to
theEngineer in charge well in time.
CLAUSE SP-2 FIXING DOWEL BARS IN CONCRETE
1 Scope
The work shall consist of fixing HYSD bars in the existing concrete
deck slab/other concrete components to facilitate bonding of
astructural component with an existing one.
At least 14 days before start of the work, the contractor shall
furnish detailed methodology of construction including sources of
supply of material, tools, equipment and appliances be used on
work, details of personnel and supervision.
Bidder 55 KDMC
and Drawings).
The contractor’s personnel shall be qualified and experienced in

repair and rehabilitation work of such nature.
Materials
HYSD bars shall conform to Section 1000.
The grout material used for fixing HYSD bars in drilled holes
inconcrete shall be obtained from a reputed manufacturer and grout
mix shall be prepared in conformity with the manufacturer’s
recommendations. The material shall beeither of the following:
(a) Two/three component low viscosity epoxy resinsystem,

having required characteristics of bondingwith concrete and
resistances to moisture penetration (Resicrete 21 or
Resicrete 212 of M/S StructuralWaterproofing Co. or
SIKADUR BTP of M/S SikaQualcrete or equivalent).
(b) Cement grout in powder form consisting ofcement, good
quality sand and admixtures whenmixed with required
amount of water forms apourable mix to be used for
bonding HYSD bars inconcrete (EXCEM – E1 manufactured
by M/s Structural Water Proofing Company or M/s
SIKADUR or equivalent).
The epoxy resin system shall conform to Clause 2803.
The cement grout shall basically be shrinkage compensated,

chloride free and of very high strength (50 MPa at 28 days). The
mixshould be capable of pumping or pouring and shall have
excellentbond strength with concrete and steel (bond strength of 15
MPawith HYSD bars at 28 days).
3 Construction Operations
The construction operation shall be in the followin sequence, and
shall be supervised by the Contractor’s Engineer in charge
wellexperienced in such works:
(i) Drill holes of required diameter and depth at

desiredlocations as shown on drawings.
(ii) Clean the hole with air blast through air nozzle of 6-mm dia
connected to air compressor to remove the drilled powder, which
may remain inside the drilled hole.
Bidder 56 KDMC
and Drawings).
(iii) Mix the required quantity of grout so that the work could be
completed within the normal setting time as specified by the
manufacturers.
(iv) Pour required quantity of mixed grout in the holes.
(v ) Insert the dowel rod in the hole where grout has
beenplaced. Move the rod up and down several times to drive out
entrappedair, if any.
(vi) Allow the curing time as per manufacturers specifications.
(vii) Inclined dowels shall be straightened to match
theirintended profile only after the grout has finally set and
requiredstrength has been achieved.
CLAUSE SP-3 CURING USING LIQUID MEMBRANE FORMING COMPOUND
1. GENERAL
Liquid membrane forming compounds are permitted to be used

bythe Engineer in charge for curing concrete for part or whole of
the total curingperiod as specified in sections dealing with
concreteconstruction. Thesemembranes reduce the loss of water
from concrete during earlyhardening period and some types of
compounds also help inreducing the temperature-rise of concrete
exposed to the radiationfrom the sun. These specifications cover
the type and use of suchcompounds. However, the use of the same
will need specific
permission from the Engineer in charge, who may require a number
of tests tobe carried out for establishing the conformity of the
product to these specification and to establish that the curing
compounand and its method of use does not have any
unacceptable effect on the ualitof concrete. The cost of the initial
acceptance testing and the quality control testing will be borne by
the contractor.
All equipment, material etc., needed for curing and protectionof
concrete shall be at hand and ready for installing before
actualconcrete begins. Detailed plans, methods and
procedureswhereby the various phases of curing and protection
shall befirmly established, shall be settled and got approved
inwriting from the Engineer-in-charge sufficiently in advance ofthe
actual concreting. The equipment and method proposed tobe
Bidder 57 KDMC
and Drawings).
utilised shall provide for adequate control and avoidinterruption or

damage to the work of other agencies.
2 CURING COMPOUNDS
1. The curing compound shall be conforming to ASTM-C-309-81,
Type-
2, white pigmented compound. The solids dissolved in vehicleshall
be either class `A’ (no restrictions) or Class `B’ (resin asdefined in
ASTM
D-883) as approved by the Engineer in charge.
2. White pigmented compound (Type-2) shall consist of finelydivided
white pigments as vehicle solids, ready mixed forimmediate use
without alteration. The compound shall presenta uniform white
appearance when applied uniformly to a freshconcrete surface at a
specified rate of application. It shall be ofsuch consistency that it
can be readily applied by praying toprovide uniform coating at
temperatures above 40C. If two coats are to be applied then it
should be applied at an interval of approximately one hour. They
shall adhere to freshly placed concrete that has stiffened or
sufficient to resist markingduring the application and to damp
hardened concrete andshall form a continuous film when applied at
a rate of 5m2/ litre.When dry, the covering shall be continuous
flexible andwithout visible breaks or pin holes and shall remain as
unbrokenfilm at least 28 days after application. It shall not react
deleteriously with the concrete.
3. The compound shall meet with the requirement of water retention
test as per ASTM designation C 156 80. The loss of water in this
test shall be restricted to not more than 0.55 kg/m2 of exposed
hours.
4. The white pigmented compound (Type 2) when tested as specified

in accordance with method E-97 of ASTM shall exhibit a day light
reflectance of not less than 60% of that of magnesium oxide.
5. It shall fulfill the requirement of drying time when tested
inaccordance with ASTM-C-309-81. The compound applied shall
bedry to touch in not more than 4 hours. After 12 hours it shall not
be tacky or tack off (peel off) concrete when walked upon nor itshall
impart a slippery surface.
Bidder 58 KDMC
and Drawings).
6. The liquid compound should be of a spray able consistency.

3 SUPPLY AND TESTING
3.1 Acceptance Testing

Prior to the approval of the brand / trade name of compound and
the source of supply and manufacturer acceptance testing shall
becarried out to demonstrate the conformance of the compound
toclause 5502. In addition, testing shall be performed to
demonstratethat no adverse / undesirable change in quality of
concrete orconcrete surface takes place as a result / by-product of
the use of the compound. These tests should be designed to check
properties such as loss of strength at 28 days of surface layer, or of
concretecube, change in surface texture, change in adhesion
tosubsequently applied layer like plaster, flooring, tiling etc.
Thetype and number of tests are to be as specified by the Engineer
in charge.
3.2 Routine Testing

The liquid membrane forming curing compound should be broughtin
the manufacturer’s original clear containers. Each containershall
be legibly marked with the name of the manufacturer, thetrade
name of the compound, the type of compound and class ofvehicle
solids, the nominal percentage of volatile material andbatch or lot
number. The lot numbers will be assigned to thequantity of
compound mixed, sampled and tested as singleproduct. The
manufacturer shall exercise the care in filling thecontainer so that
all are equally representative of the compoundproduced.
2. Curing compound to be used on site shall be got tested at least
14days in advance so that the result of water retention tests,
reflectance drying, etc, are available before it can be permitted for
use. All of the filled containers represented by the approved sample
shall then be sealed to prevent leakage, substitution or dilution. The
Engineer-in charge or authorised representative should mark each
container represented by the samples with a suitable identification
mark for later identification and correlation and shall be kept in
store with double lock arrangements. One key shall be kept with
the Contractor andtheRandom samples shall be collected from
other with Engineer.ebvaetchry of the compound. Frequency of
random sampling shall bedoneas irected by the Engineer in charge.
Bidder 59 KDMC
and Drawings).
The Contractor shall provide samples and labour for collecting

samples free of cost. Testing shall be carried out by agency
approved by the Engineer in charge and in presence of
respresentative.
4. METHOD OF APPLICATION
The compound shall be sprayed using mechanical sprayer of
approved design to ensure uniform and continuous membrane on
the concrete surface. The coverage shall be at the rate specified by
the manufacturer or at the rate of 4 m2 per litre or as specified by
the approved by the Engineer in charge.Field trials shall be
conducted tofacdecideeffective coverage rate, which depends upon
surface finish. The Engineer in charge after verification of the field
trials and based on the actual experience shall order the rate of
application as needed for achieving the proper curing. With a view
to ensure thorough coverage, approximately one half of the
compound for a given coverageapprotxareas should be applied by
moving the spray gun back and forth in one direction and the
remaining half at right angles to thisdirection. In case the
application is still not found uniform, the Contractor shall have to
apply the second coat as and when directed by the Engineer in
charge. If a second coat is to be applied, it shouldbe applied
approximately after an interval of one hour. The curing compound
shall generally be applied as soon as the bleeding water or shine
disappears, leaving dully appearance.
If surface treatment by roughing, hand brushing etc., is required

(e.g.as in case of road pavements) the curing compound should
beapplied immediately after the same. Equipment for spraying
curing compound shall be of pressure tank type (5 to 7 kg/cm2)
withprovision of continuous agitation. A curing jumbo with
multipletravelling spray fans shall be provided for effective spray.
Spraying on concrete lining shall be done in such a way that the
greenconcrete is not disturbed or damaged or any foot impression
left. Necessary schemes or spraying by mechanised means shall
be gotapproved by the Engineer-in-charge. However, in emergency
forvery small areas / patches) it can be applied with wire or bristled
brush.
Bidder 60 KDMC
and Drawings).
CLAUSE SP-4 ADDITIONAL TECHNICAL SPECIFICATIONS FOR ROAD

SIGNS
1. General
The Colour, configuration

The Colour, size & location of all traffic signs for the project road
shall be as specified in the drawings and in the absence of any
details or any missing details, the signs shall be provided as
directed by the Engineer in charge.
1.1 The sign shall be reflectorised as shown on the drawings or as

directed by the Engineer in charge. The signs shall be of retro
reflective type and made of prismatic reflected sheeting as per Cl.
1.3 fixed over aluminium sheeting as per these specifications.
1.2 The cautionary and mandatory signs shall be fabricated through
process of screen-printing. In regard to informatory signs with
inscriptions, the message shall be of cut out letters made in the
transparent overlay film pasted over the base sheeting with
pressure sensitive or as instructed by the manufacturers or as
directed by the Engineer in charge.
2 Material
The various materials and fabrication of the traffic signs shall

conform to the following requirements:
2.1 Concrete: - Concrete shall be of the grade shown on the contract

drawings or otherwise as directed by the Engineer in charge.
2.2 Reinforcing Steel: -Reinforcing steel shall confirm to the
requirement of IS : 1786 unless otherwise shown on drawing.
Bidder 61 KDMC
and Drawings).
2.3 Bolts, nuts, washers: -High strength bolts shall conform to IS:
1367
Whereas precision bolts, nuts etc. shall conform to IS: 1364.The
bolts and nuts shall be galvanised (zinc coated, 0.55 kg/sqm
minimum single spot) and galvanising shall conform to relevant
ISspecifications. Plates
2.4 Plates and support: Plates and support sections for the sign posts
shall conform to IS: 226 and IS: 2062 or any other relevant IS
specifications. The plates and supports shall begalvanised (zinc
coated,
0.55 Kg per Sqm. minimum single spot.) and galvanising
shallconform to relevant IS specifications
2.5 Aluminium:-Aluminium sheets used for sign boards shall beof
smooth, hard and corrosion resistant aluminium alloy conforming to
IS:
736 – Material designation 24345 or 1900. The back of the sheet
will be painted with two coats of Epoxy paint
2.6 The thickness of sheet shall be 3 mm for all types of signs supports
3 Structural Details
The structural details for supports shall be as per the contract
drawings and or as directed by the Engineer in charge.
4 Retro-reflective sheeting
4.1 General requirements
The retro-reflective sheeting used on the sign shall consist of the
white or coloured sheeting having a smooth outer surface, which
has the property of retro-reflective over its entire surface. It shall be
weather resistant and show colour fastness. It shall be new and
unused and shall show no evidence of cracking, scaling, and
pitting, blistering, edge lifting or curling and shall have negligible
shrinkage or expansion. A certificate of having tested the sheeting
for these properties in an unprotected outdoor exposure(stating
retained reflection of 80 %) facing the sun for three years and its
having passed these tests shell be obtained from a reputed
laboratory, by the manufacture of the sheeting.
The reflective sheeting shall be of wide angle prismatic lens type of
ASTM-Type – IX.
Bidder 62 KDMC
and Drawings).
should be applied to the sign substrate at room temp. 18 C,

transparent waterproof plastic having smooth surface. The coeff
ofretro reflective as determined in accordance with ASTM standard
E810 shall give the minimum values as indicated in table given
below.
TABLE – 1
Minimum Coefficient of Retro-reflection for retro-reflective
sheeting Prismatic lens type (candelas / lux / sq. m)
Obse. Entrance White Yellow Green Red Blue

Angle (in Angle (in
deg) deg)
0.1 -4 660 500 66 130 30
0.1 +30 370 280 37 74 17
0.2 -4 380 285 38 76 17
0.5 +30 215 162 22 43 10
0.0.5 -4 240 180 24 48 11
0.5 +30 135 100 14 27 6
1.0 -4 60 60 8 16 3.6
1.0 +30 45 34 4.5 9 2
When totally wet, the sheeting shall not show less than 90% of the
values of retro reflectance indicated in Table 1. At the end of
7years, the sheeting shall retain at least 75% of its original
retroreflectance.
5 Messages / Borders
5.1 The messages (legends, letters, numerals etc.) and bordersof

Cautionary / Regulatory sign boards shall be screen printed.Screen
printing shall be processed and finished with materials in a manner
specified by the sheeting manufacturer and shall be bonded with
the sheeting in the manner specified by the manufacturer. The
messages (legends, letters, numerals etc.) and borders of
information signs,shall be of cut letters made in transparent overlay
film pasted over the sheeting with pressure sensitive adhesive or
as instructed by the manufacturers or as directed by the Engineer
in charge.
Bidder 63 KDMC
and Drawings).
5.2 For screen printed transparent coloured areas on white sheeting,the

co-efficient of retro-reflection shall not be less than the values of
corresponding colour in Tables-1.
5.3 Cut out messages and borders, wherever used, shall be madein
transparent film applied on base sheeting with pressure sensitive
adhesive with the coefficient of retro reflection shall not be lessthan
the values of corresponding colour in Table-1. For theackground
colour of the sign the coeff of retro reflection shall not be less than
that specified in Table -1 for the respective colours.
6 Colour
Colour shall be as specified and shall conform to the requirements
of Table 2. Conformance to colour requirements shall be
determined spectra photo metrically in accordance with ASTM E
1164, with instruments utilizing either 45/0, or 0/45
illumination/viewing conditions and tolerances asdescribed in
ASTM E 1164 for retro reflective materials.
Table 2
Reflection
Limit (y)
Colour x y x y x y X y Min Max
The four pairs of chromaticity coordinates determine the acceptable

colour in terms of CIE 1931 standard colorimetric system measured
with standard illumination source D65-these colours are equivalent
to those listed in ASTM D4956 using source C
The colour shall be durable and uniform in acceptable huewhen
viewed in daylight or under normal headlights at night.
7 Adhesives
The sheeting / film shall have a pressure sensitive adhesive of the
aggressive tack type requiring no heat, solvent or other
preparationfor adhesion to a smooth clean surface. The adhesive
shall beprotected by an easily removable liner (removable by
peelingwithout soaking in water or other solvent) and shall be
Bidder 64 KDMC
and Drawings).
suitable for the type material of the base plate such that it shall not
be possibleto remove the sheeting from the sign base in one piece
by use ofsharp instrument. The adhesive shall form a durable bond
tosmooth, corrosion and weather resistant surface of the base
plate.In case of pressure sensitive adhesive sheeting, the sheeting
shallbe applied in accordance with the manufacturer’s
specifications.
8 Fabrication
8.1 Surface to be reflectorised shall be effectively prepared to receive
the reflective sheetingThe aluminium shall be de greased either
byacid or hot alkaline etching and all scale / dust removed to obtain
a smooth plain surface before the application of retro reflective
sheeting. If the surface is rough, approved surface primer may
beused. After cleaning, metal shall not be handled, except by
suitabledevice or clean canvas gloves, between all cleaning and
preparationoperation and application of reflective sheeting / primer.
There shall be no opportunity for metal to come in contact
withgrease oil or other contaminates prior to the application of retro
8.2 Complete sheets of the material shall be used on the signs except
where it is unavoidable; at splices, sheeting with pressure sensitive
adhesives shall be overlapped not less than 5 mm. Where screen
printing with transparent colours is proposed only but jointing shall
be used. The material shall cover the sign surface evenlyand shall
be free from twists, cracks and folds. The transparentoverlay film in
which cutout messages have been made shall bebonded with
sheeting in the matter specified by the manufacturer.
9 Warranty and Durability
The contractor shall obtain from the manufacturer a seven year

warranty for satisfactory field performance including stipulated retro
reflectance of the retro reflective sheeting of Prismatic lens type
and.that of transparent film and submit the same to the Engineer in
chargeI, a seven year warranty for satisfactory in field and addition
performance of the finished signs with retro reflective sheeting of
Prismatic lens type,inclusive of the screen printed or cutout letters /
legends,transparent film an their bonding to the retro reflective
sheeting shall be obtained from the contractor / Supplier and
passed on to the Engineer in chargeThecontractor / Supplier shall
also furnish a certification that the signs and materials supplied
against the assigned work meets all the requirements and carry the
stipulated warranty
Bidder 65 KDMC
and Drawings).
Warranties should be given in original and should havelegal

jurisdiction in India. Warranties given by power ofattorney holders
will not be acceptable.
Processed and applied in accordance with

recommendedprocedures, the reflective material shall be weather
resistantand following cleaning, shall show no appreciable
discoloration, cracking, blistering or dimensional change and shall
not haveless than 50 % of the specified minimum reflective
intensityvalues (Tables 1) when subjected to accelerated
weathering for1000 hours, using type E or EH weatherometer
(AASHTODesignation M-268).
10 Installation
10.1 Sign posts, their foundation and sign mountings shall be so
constructed as to hold these in a proper and permanent position.
Sign supports shall be of Galvanised structural steel and shall be
firmly fixed to the ground by means of properly designed foundation
or as shown in the contract drawings. The work of foundation shall
conform to clause 801.4.4.
10.2 All components of signs and supports, excluding the back side of
aluminium sheet and the reflective portion shall be thoroughly
descaled, cleaned and galvanised (zinc coated, 0.55
Kg/Sqm.minimum single spot.) and shall conform to relevant IS
Specifications.
10.3 The signs shall be fixed to the posts by welding and/or boltsand
washers as shown in the drawing. After the nuts have
beentightened, the tails of the bolts shall be furred over with a
hammerto prevent removal.
11 Foundation for Support
11.1 Foundation for supports of sign boards with single support shall
beby making excavation in all type of strata to the sizes and level
as shown in relevant drawings and fixed with M-20 grade cement
concrete during installation.
11.2 Foundation for supports of sign boards with two or more
supportsshall be made by boring holes in all types of strata to the
sizeslevels as shown in relevant drawings and fixed with M-
20grade cement concrete during and installation. All concrete
workswill be carried out as per relevant MORT&H Specification.
Bidder 66 KDMC
and Drawings).
CLAUSE SP-5 ADDITIONAL SPECIFICATIONS FOR TRAFFIC

MANAGEMENT AND DIVERSION
The contractor shall prepare and submit to Engineer in charge

within one month of the date of commencement of work, a detail
trafficdiversion plan as per the requirement of traffic authorities.
Thecontractor shall have to carry out the modifications in the
trafficdiversion plan at various stages of work as required.
Thecontractor shall maintain liaison with the traffic police /
authorities so as to ensure smooth flow of traffic at all stages of the
workwithout causing inconvenience to the traffic.
1 Traffic Rotaro
The contractor shall provide traffic rotaro showing trafficdirection

made up of four blinkers mounted on M.S. Frame of 5x50x6mm
size 250 Hz frequency electrically operated at both ends of
thecordoned area for help and guidance of road users.
Necessaryarrangements for supply of electricity shall be made by
the contractor.
2 Road Delineators
Road delineators as per IRC-79 and as per relevant drawings and

as directed by Engineer in charge shall be fixed at suitable intervals
to have a suitable guidance to the road users at the night time for
smoothflow of traffic. Delineators shall be fixed firmly in the ground.
Alsored flags, cat eye reflectors shall be fixed on the barricades.
Alternative arrangements shall also be kept ready in case of failure
of electricity.
Bidder 67 KDMC
and Drawings).
3 Signs, lights, barriers and other traffic control devices shallbe

provided and maintained in a satisfactory condition till such time
they are required as directed by the Engineer in charge, so as
toensure smooth and safe traffic on the road throughout the length.
CLAUSE SP-6 SPECIFICATIONS FOR INTER-LOCKING CONCRETE

PAVING BLOCKS
1. Quality
The block for the paving works shall be as per IS : 2187 part-II –
Paving Blocks. The blocks shall be 60 mm thick of quality
concretegrade M30 having specified size and type with grey or red
orcombination of them.
2. Sub-base & Base

Over the prepared and consolidated subgrade a layer of Sub-base
using crushed aggregate shall be laid to falls and slopes to a
compacted thickness of 100 and compacted with Compactor. Over
the prepared sub-base, a layer of 3 mm and down fine sand shall
be laid to a thickness of 50mm and accurately screed and leveled
and compacted to 38mm in thickness and to required falls and
slope to the satisfaction of the Engineer in charge.
3. Layers
The blocks shall be laid on top of the prepared base in
requiredpattern as directed by the Engineer in charge. On
completion of the layinwork, approved fine screened sand shall be
spread over the paving and the joints filled with fine sand
compacted as directed by the Engineer in charge. Extra sand on
the surface shall be removed by brush. When require, edge blocks
shall be cut clean and sharp withapproved tools and as per
manufacture’s instructions. The cut edgesshall be rubbed smooth
before lying. Compaction with a powervibrating plate (Wacker
Bidder 68 KDMC
and Drawings).
model VPH 70) shall be used suitable as recommended by the

approved proprietary manufacturer. Any blocks damaged during
laying shall be replaced. The entire work ofthe installation and
materials shall meet the approval of the Engineer in charge.
CLAUSE SP-7 STREET LIGHTING INSTALLATIONS
1 Scope
The scope of Bidder/ Contractor shall be design, manufacture,

packing, delivery at site with all accessories, items, equipment
complete, installation, testing, commissioning of the entire street
lighting system for the Flyover portion, slip road and the ROB
including the cost for intake supply to Pillar Boxes.
The Bidder/ Contractor shall coordinate with local supply authority

for supply to Pillar Boxes necessary to cater to all street lighting
distribution networks. As such the scope of Bidder/ Contractor shall
start from design, fabrication, supply at site, installation, testing,
commissioning of Pillar Boxes and to complete all down stream
distributions.
All the materials shall be brand new and the bidder shall follow all
the relevant Indian Standard Codes, International Codes as
applicable and the Indian Electricity Rules and Acts as amended up
to date together with this document.
The document here provides the basic specification for the

equipment, components, instruments, and auxiliaries, accessories
to achieve the control, protection, and requirement of the system
and the job in totality shall be as per best practices.
2 Standards
A few Standard Codes are noted below for ready reference:
i) IS: 1913 General and Safety requirements for light fittings.
ii) IS: 1944, 1970 Code of practice for lighting public thorough
fares.
iii) IS: 3528 Water proof electric lighting fittings.
Bidder 69 KDMC
and Drawings).
iv) IS: 3553 Water tight electric lighting fittings.

v) IS: 1239 M.S. Tubular and other wrought steel pipe fittings.
vi) IS: 2149 Luminaries for street lighting.
vii) IS: 3043 Code for practice for earthing.
viii) Indian Electricity Act and Rules.
ix) National Electric Code, Part 5 .
x) CIE Publication No. 68 xi) IS: 116 Circuit Breakers for AC
system xii) IS: 159 Bus bars and Bus bar connections.
xiii) IS: 3072 Code of Practice for installation of switchgear.
xiv) IS: 3106 Code of Practice for Selection, Installation
andvMaintenance of Fuse (up to 650 Volts).
xv) IS: 3202 Climate Proofing of Electrical Equipment.
xvi) IS: 3427 Metal enclosed Switchgear and Control Gear.
xvii) IS: 3837 Accessories for rigid steel conduits.
xviii) IS: 4047 Heavy Duty Air Brake Switches and Composite
Switch Fuse.
xix) Units for Voltage not exceeding 100 Volts.
xx) IS: 4064 Switch Fuse Units for Industries etc.
xxi) IS: 4237 General requirements for switchgears not
exceeding 1000 Volts.
xxii) IS: 5133 (Part-I) Sheet Steel Boxes.
xxiii) IS: 5216 Guide for safety procedures and practices in
electric work.
xxiv) IS: 6381 Specifications for construction and testing of
electrical apparatus.
xxv) IS: 1947 Flood Lights
xxvi) IS: 2147 Degree of Protection provided for enclosure for
Switchgears.
Bidder 70 KDMC
and Drawings).
xxvii) IS: 2208 HRC Cartridge Fuse Units up to 650 Volts.

xxviii) IS: 2251 Code of Practice for Danger Notice Plates.
xxix) IS: 2274 Code of Practice for wiring installation (exceeding
650 Volts).
xxx) IS: 2667 Fittings for rigid steel conduits for electricwiring.
xxxi) IS: 2675 enclosed distribution fuse board’s cutouts for
voltage up to 1000 Volts.
xxxii) IS: 2705 Current Transformers.
xxxiii) IS: 722 Three Phase Watt Hour meters with MDI.
xxxiv) IS: 732 Electrical wiring installation (up to 650 Volts)
xxxv) IS: 1554 PVC Insulated Cables -Heavy Duty.
All codes and standards referred here shall be of up-to-date

version. Where not specified otherwise the installation shall
generally follow the Indian Standard Code of Practice or the British
Standard Code of Practice in the absence of Indian Standard.
3 General
The street lighting installation for the project shall be carried out by
use of out door type, weather proof luminairs (IP 66), to be
mounted on octagonal steel poles hot dip galvanized inside &
outside.
Electric power supply at 415 volt, three phases, four wires, 50 Hz to

be for each circuit shall be fed from the designated feeder Pillar
Box.
Electric power shall be distributed to the street lighting poles

through electric cables laid below ground and/ or through HDPE
pipe buried under ground and/ or through GI pipe laid in
crashbarrier and shall be so distributed that equal load balance in
all three phases is achieved. Individual control MCB with Pole
junction box shall be providedon each pole. The terminal box shall
be weather proof, having gasketed cover. Moreover, Junction
Boxes shall be inserted in crashbarrier near each pole for looping
main cable and branching of the pole distribution.
Bidder 71 KDMC
and Drawings).
The street light poles shall be earthed individual y with Rod

electrode type earth station & 2 Nos. of G I wire shall be used for
earthing purpose or else for poles on crash barrier two nos.
earthing shall be connected with the earth network for each pole.
Electric cable required for the street lighting installation shall be

1100 Volt grade, armoured, XLPE insulated PVC sheathed
stranded Aluminium conductor of suitable rating.
For automatic ON/OFF operation of the street lights, programmable

type automatic timer shall be provided in the street light feeder
pillars. They should have energy saving feature.
All street lights shall be controlled from the outdoor type streetlight
control panel/feeder pillars the locations of which shall be decided
as per site suitability and approval of the Client during detail
Engineer in chargeing and execution period. The location of the
Feeder Pillar Box shall be decided during execution depending on
the location of availability of supply point from supply authority.
4 Lighting Poles
The street lighting installation for the project shall be carried outby
use of out door type, weatherproof luminaries, to be mounted on
octagonal hot dip galvanized poles inside & out side. The street
light poles shall be fabricated from heavy duty cold rolled sheets
and shall be continuously tapering.
Height of street li hting pole shall be 7.5 meter or 9 meter or more

as per design requirement for the road widths. Hot dip
galvanization at inside and outside shall conform to BS 729 Part I,
BS 5135, IS 2629-1985, IS: 2633-1972 etc.
The galvanization shall be 65 microns and the same shall be

recorded and results shall be furnished while bidding.
The street light poles shall be provided with suitable size of

foundation plate, with suitable opening for 3 -4 cables and holes for
foundation bolts.
Bidder 72 KDMC
and Drawings).
The terminal box shall be provided with Epoxy terminals and MCB’s
shall be concealed inside the pole.
The pole fabrication shall conform to the drawings and where such
drawing is not available, the Contractor shall make such drawing
and get it approved before fabrication.
For fixing earth wire, bolts shall be welded to the pole and provided
with suitable nut, washer and spring washer.
The pole shall be manufactured and tested as per relevant IS and
test certificates shall be submitted to Engineer-in-Charge for a
pproval.
5 Pole Terminal Box

The junction box enclosure shall be made up of cast Aluminum
weather proof, splash proof, and vandal proof enclosure suitable for
mounting in pole internally with suitable clamping/ fixing
arrangement. The enclosure shall have recessed hinged door with
neoprene gasket and locking arrangement.
Each enclosure shall be adequately sized to house terminal blocks

to loop in and out 2-3 Nos. 4C x 25/35 mm2 cables, Neutral link
and MCB s of suitable rating as per load requirement with base. All
above components to be rigidly mounted on back plate.
Suitably sized removable type gland plate for armoured cables to

accommodate heavy duty double compress on brass gland with all
accessories for effective earthing / bonding of cable armourand
pole body shall be provided. The box shall have earth terminalon
inside and outside for connecting earth wire.
3C x 2.5 mm2 stranded copper conductor, heat resistant PVC

insulated cable to be provided from the pole terminal box to each
street light fitting.
6 Pole Bracket
The pole bracket shall be suitable for erection of street lighting
luminaire.
Bidder 73 KDMC
and Drawings).
Pole bracket shall be made from 60 mm diameter ‘B’ class

galvanized Iron pipes.
A stopper shall be provided with 3 nos. holes at 120 degrees for

proper fixing of the bracket on the pole top.
7 Street Lighting Fittings:
7a Fittings Suitable for LED

Green Line Extra BRP 32264 LED CW 125 FGS S1 PSU GR 137
Watt LED of M/S Philips or equivalent from M/S GE, M/S Bajaj, M/S
Crompton, M/S Schreder
All the luminaires shall be mechanically strong, electrically safe,

chemically inert of atmospheric pollution, vibration proof and
aesthetically good.
The assembly shall be such that easy installation, operation and

maintenance shall be possible.
The housing shall be pressure die cast with options of cover glass
and poly carbonate cover.
Shall comply to IS 1944, IEC 60598, IS 10322.
The spread, throw and glare control mark of the luminaires shall be
compatible to the lane width.
8 Street Light Control Panel/Feeder Pillar

The control panel shall be suitable for outdoor installation and all
relevant codes of practices shall be applicable. The pillar shall be
weather proof and water proof and shall be suitable for IP65.
The control panel shall be made from 14 SWG CRCA sheet steel.
The control pillar shall have 2 separate compartments with
separate doors. One compartment shall be for incoming supply
switch gears and energy meter etc., and shall have sealing
arrangement. The other compartment for consumer use shall have
control and power switchgears for outgoing. All the equipment in
the pillar box shall be erected on 2mm thick
Bidder 74 KDMC
and Drawings).
galvanized iron plate, and this plate shall be properly connected to

the earth bar. Energy saving features shall also be there.
All power and control wiring inside the control pillar shall be with
stranded copper conductor wires with lugs / ferrules as per
requirement and clamped at both the ends.
For termination of incoming and outgoing cables, epoxy insulators

with studs and lock nuts shall be provided.
A detachable gland plate made out of 3 mm thick galvanized

iron/Aluminum sheet shall be provided at the pillar bottom.
Timer control for switching streetlights ON/OFF is required to be

provided.
Contractor to provide KWH meter and CT’s as approved by the

power Supply Company and get the same calibrated before
installation. Certificate shall be submitted after commissioning the
equipment.
Entry of cable to pillar box shall be from bottom and PVC shrouds
shall be provided between phases, distributors.
Feeder pillar foundation shall be M30 Grade Concrete, 500 mm

above ground level.
9 Pole Foundation
The pole foundation shall be of concrete grade M30 and size

shown in the drawing with necessary excavation in all types of soil,
murum or rock.
A octagonal shaped linth of size shown on the drawing above

ground level shall be provided. The plinth shall be plastered
smoothly and painted with 2 coats of Cement paint from all sides.
The plinth shall be of concrete grade M30 and it shall be cast along
with foundation.
The foundation shall have 2/3/4 nos. of G I class B pipe embedded

for cables.
Bidder 75 KDMC
and Drawings).
10 Earthing works:
The earthing system shall follow IS 3043; however, a few salient
features are discussed below:
10a Earthing for Feeder Pillar Box
A GI Pipe of 40 mm. dia. 3.0 meter long shall be provided with a

funnel on the top of pipe. A funnel with wire meshes that isused for
pouring of water shall be screwed to the pipe. The pitshall be free
from hard rock and surrounding soil shall be damp. Alternate layers
of a homogenous mix of charcoal salt and low resistivity soil shall
be provided for refilling the earth pit. The depth of earthing pit
should be 3.0 meter. The lower part of pipe(about 1.5 meters) shall
have holes of 12 mm dia. at the interval of 150 mm. Earthing
resistance shall not exceed more than 1 Ohms. 25x3 mm GI strips
shall be used for Pillar Box earthing connection to earth pit.
10b Earthing for Poles
One number 20 mm diameter 2.5-meter-long M S rod, electrode

shall be provided for each pole. For earthing of the Poles 2 nos. 8
SWG galvanized iron earth wires shall be used. For Poles erected
on crash barrier, the pole shall be doubly connected to the running
earth grid.
10c Earth pits
Solid block masonry chamber plastered smooth inside shall be

constructed up to 450 mm resting on PCC below ground. A Cast
Iron Chamber Frame with concealed hinged CI cover with lifting
hook shall be embedded in concrete on top of the chamber.
An earthing lead shall be brought out by fixing GI strip of 50 x 6mm
and by using 9 mm diameter GI/Brass nut bolt, and set of washers.
Suitable GI Clamps shall be provided on the GI pipeinside chamber
for taking tap off for earthing leads
Bidder 76 KDMC
and Drawings).
CLAUSE SP 9 GEOTECHNICAL INVESTIGATIONS (DETAILED

EXPLORATION)
1. SCOPE OF PROPOSED INVESTIGATIONS

The exploratory Geotechnical Investigations are required to be
conducted at location. All geotechnical investigation shall be done
through KDMC/PMC approved reputed Agency.
Preliminary investigations have been carried out along the

alignment. It is proposed to carry out detailed explorations as per
Section 2400of MORTH Specifications for Road and Bridge Works
(2001). This work shall be considered incidental to the foundation
works and nothing extra shall be paid.
The scope of the geotechnical investigation is discussed below and

is given in the Bill of Quantities.
The present scope of work includes drilling of exploratory

boreholes, collection of disturbed and undisturbed samples,
conducting Standard Penetration Tests and Vane Shear Tests and
all other required laboratory tests.
2. SPECIFICATIONS
FIELD WORK
a) Bore holes
The borehole diameter shall be of adequate size (atleast 150 mm)
to obtain 100mm diameter undisturbed samples from the borehole.
The borehole depths are likely to vary depending on location.
Field testing in boreholes includes Vane Shear Tests and Standard

Penetration Test as stipulated by the Engineer in charge during
execution.
Sampling in boreholes includes undisturbed and disturbed

sampling of all types of materials, rock cores and groundwater. All
field and laboratory testing shall be conducted in accordance with
relevant IS Codes and as stipulated by the Engineer in charge.
Bidder 77 KDMC
and Drawings).
b) Drilling in Soils Other Than Rock

The boreholes should be drilled at the locations indicated on the
drawing to be furnished by the Engineer in charge.
Rotary drilling rig preferably hydraulically operated, with drill pipes
and drill bits, swivel type double tube core barrels of M-series with
matching diamond bits/triple tube core barrels or type as required
by the Engineer in charge, undistributed soil samplers like push
sampler/piston samplers, SPT equipment, drilling mud chemicals,
all consumables and all other accessories and spares as required
for investigations in all kinds of soils and rocks shall be mobilized
by the contractor. The rotary drill method shall be preferred to shell
and augur method while boring in soil. Calyx type drilling rigs shall
not be allowed under any circumstances. The method of advancing
the borehole in soil overburden by establishing the sides of the
boreholes by drilling mud (Bentonite) is considered preferable to
casing of the borehole. Drilling should be carried outing such a
manner as to limit disturbance of the soil to be sample do tested to
a minimum. Washing tools should have proper side jets and under
no circumstances will bottom discharging tools be permitted. The
insert casing shall be sufficient to allow for in-situ sampling and
testing with standard sampling and testing tools.
Electronic the odolite and other necessary survey equipment shall

be mobilized along with necessary personnel for operation of the
same for positioning of the borehole locations and measuring
ground levels.
All personnel required for round-the-clock operations including a

graduate Engineer in each shift should be available at site. All such
personnel mobilized for each shift of 12 hours shall have minimum
of three years of experience in the same type of job. The project in-
charge shall be a post-graduate geotechnical Engineer in charge
with minimum of five years of experience in the same type of job.
The borings shall be carried out in accordance with relevant Indian

Standard Code of Practice and the requirements stated herein. The
boring, sampling and in-situ testing shall be carried outin a manner
approved by the Engineer in charge who shall have the right to
order alternative procedures if he is not satisfied with the quality or
accuracy of the work.
The observations during boring shall be put down in such a

manner, so that each change in strata is accurately determined to
Bidder 78 KDMC
and Drawings).
the satisfaction of the Engineer in charge. During the boring

operation, particular attention shall be paid to the disturbed material
washed up or brought up by the shell and auger, and these shall be
described in the boring logs. These disturbed materials should be
preserved inpolythene bags with tags stating borehole reference,
depths, nature of soil etc.
The work of drilling in soil shall be carried out in such a manner that
disturbed as well as undisturbed samples of soil can be
conveniently collected at the required depths/intervals, and
penetrometer tests can be carried out if required. The Contractor
shall adopt such a method, which will permit the collection of
samples indicating the grain size distribution of natural strata
without loss of fines, covering the entire depths.
Water samples shall be collected from the boreholes. Water

samples shall be collected prior to addition of Bentonite to
boreholes. If this is not possible then prior to collection of water
samples, the borehole shall be dewatered by about half a meter
depth and water allowed rising back prior to sampling. Ground
water level for eachborehole shall be checked during boring
operation and shall be recorded in borelog.
The drilling operations may be interrupted for collecting the

samples, probing and conducting penetrometer tests etc. The
casing pipes shall not be removed unless directed by the Engineer
in charge. Even after removal of the casing, a piece of pipe should
be left in the bore hole to identify the location.
The Contractor shall ensure that sand-blow conditions do not

develop while drilling, sufficient surcharge of water or drilling mud
should be maintained all throughout the drilling operation.
In the exploration programme the contractor shall associate with

the provisions of IS:1892.
c) Undisturbed Soil Samples

In overburden undisturbed samples shall be recovered from the
borings at intervals not exceeding 3m and at every change of
strata.
Bidder 79 KDMC
and Drawings).
The undisturbed sampling shall conform to IS Code 2132 (1972).

Undisturbed samples shall be collected in returnable tubes of
100mm internal diameter. Attempts should be made to collect
undistributed soil sample of 500mm to 600mm in length.
The sample tube shall have a proper identification mark painted

onit (e.g. borehole reference, depth, location, arrow mark indicating
bottom end of the sample tube etc.). The moisture in undisturbed
samples shall be carefully preserved by sealing both ends of the
sample tube by applying a double coat of cotton waste and paraffin
wax.
d) Disturbed Soil Samples
Disturbed soil samples shall be collected from boreholes. These

shall include soil samples collected from the split spoon samples
andalso from the cutting edges of UDS. The samples shall be
stored in plastic bags.
e) Drilling in Rock
In general, boreholes should be taken to relatively hard strata.

Should rock be encountered in soil borings, it shall be proven by
core drilling for a penetration of at least 3 m, or as directed by the
Engineer in charge. Rock cores shall be retrieved in minimum NX
size by using swivel type double or triple tube core barrels with a
suitable core catcher and diamond bit. Single tube core barrels or
calyx type drills will not be permitted. Drilling mud or any other fluid
likely to aggravate core slips shall not be used.
If required, in all types of rock, the borings will be extended more

than the depths specified above, as directed by the Engineer in
charge. When drilling in all types of rock, instructions given in IS
4078, 4464, 5313and 6926 shall be followed.
During the drilling operation, particular attention should be paid to

get the core recoveries and rock quality designations of the highest
standards. Percentage core recovery and RQD should be indicated
continuously from the depth starting from the level of Highly
weathered rock. If the core is broken by handling or during drilling,
the fresh broken pieces shall be placed together and counted as
Bidder 80 KDMC
and Drawings).
one piece. This has to be done as the cores come out during
drilling, with the permission of Engineer in charge.
Soil samples and rock cores collected continuously to full depth of

boreholes should be clear marked with good quality oil paint.They
shall be designated by number, arrows, depths, borehole to which it
belonged etc. for the purpose of identification at a laterdate. Sketch
pens or marker pens shall not be used for writing numbers on core
pieces.
When bedrock is encountered, drill hole shall continue atleast three

meters in sound rock to ensure the continuity of the strata. If
weathered or soft rock is met with; drill hole shall continue 5 meters
into the rock layer. However if heavily shattered rock due to various
weathering process or weak rock zone susceptible to erosion when
subjected to action of flowing water or any other types of rock
which can not be recommended as a founding strata is met with
continuing 6 to 7 meter s then the drilling shall continue through the
weak zone well into the sound rock below the top weak zone. Such
incidences shall be brought to the attention of the Engineer in
charge and no borehole shall be terminated without the approval of
the Engineer in charge.
The characteristics/strength of rock with respect to weathering,

hardness, joints and bedding and rock quality designation (RQD)
as presented in Tables 2,3,4 and 5 in Appendix Iof IRC 78-1983
shall be followed and the same shall be indicated in the bore logs.
Drilling through rock being a specialised work, every care shall be

taken to notice and record any small change during drilling. The
time required to drill through a certain depth, amount of core
recovery, physical condition, length of pieces of core, joints, colour
of water residue, weathering, and evidence of disturbanceand other
effects shall be carefully noticed and entered in the drill/core log.
The directions given in IS 5319 – “Guide for Core Drilling
Observation” may be followed while preparing the core logs.
The core boxes provided by the Contractor shall be sturdy and of

good quality G.I. M.S. 18 Gauge and shall be made according to
the sketch on Page 6 of IS 4078 (1980) with locking arrangements
and compartments. The core boxes shall be painted inside with oil
paints. Each and every core piece extracted from the core barrel
shall be placed in core boxes in the proper sequence of occurrence
Bidder 81 KDMC
and Drawings).
from top downwards. The starting and finishing depth of each run
shall be recorded on the core box compartments in oil paint as the
cores are placed. They shall be sequentially numbered on the four
sides and the lid. The name of the project, drill hole reference, and
the depth of the core obtained shall be prominently painted on the
lid with oil paint.
The depth of cores below ground level shall be indicated at about

every 1.5m interval by writing the depth in indelible ink on wooden
spacers that shall be inserted in their correct positions in the box.
Similarly, the exact depth of any change in stratum and failure to
recover the core etc. shall be recorded. The labeling of core
samples rock shall be done in accordance with the Appendix D of
IS 4078 of 1980 or as directed by the Engineer in charge.
Each core box shall house samples not more than 6 m long in total.
While placing the core samples in the wooden boxes, it should
been sured that the direction and sequence of core placement is
not altered. The core run shall be restricted to 500 mm to 600 mm
length at a time and the core sample removed as directed by the
Engineer in charge. The cores and core boxes shall be transported
to a storing place as indicated by the Engineer in charge.
The Contractor shall submit five copies of cabinet size
(160mmx120mm) colour photographs of the selected cores as
specified by the Engineer in charge.
An arrangement should be made for collection of wash watery
installing a top socket with a cross pipe at the top of the casing
before the start of rock drilling. The side of the casin should be well
packed near the top of the hole to prevent leakage. Wash water
should be collected in buckets and allowed to settle. A record of
wash water shall be maintained indicating colour, change in colour
and type of wash water (i.e. thick slurry or clean water)
Bidder 82 KDMC
and Drawings).
The number of revolutions per minute for the rock drilling shall be
kept low (about 200 RPM) for "NX" size bits, with suitable reduction
gear and bit pressure kept to a minimum without rod vibration
on"chatter". The rate of penetration for every 250 mm shall be
observed during rock drilling and recorded.
Field bore logs shall be submitted to the Engineer in charge after

completion of each borehole at site or as demanded by the
Engineer in charge.
IN-SITU TESTING
The item covers conducting in-situ test and may include;
Standard Penetration Tests.

Field Vane Shear Tests
a) Standard Penetration Test in Boreholes

The Standard Penetration Test [SPT] shall be carried out in
boreholes at intervals as directed by the Engineer in charge.
Intervals shall not exceed 3 m according to Indian Standard Code
of Practice.
For details of the sampling tube (spoon) and equipment and

procedure for conducting a penetrometer test, the IS Code
2131(1963) shall apply. The driving monkey should be provided
with suitable arrangement for controlling the height of fall. It should
be ensured that blowing in of fine sand is avoided while conducting
penetrometer tests. For this purpose, it may be necessary to use
mud (Bentonite) circulation or create surcharge pressure.
For SPT the blow count shall be recorded at intervals of 150mm,

for a total penetration of 60mm. The SPT blow count shall be
reckoned as the total number of blows for the second and third
penetration increments of 150mm.
Every attempt shall be made to recover the full sample from the
standard split spoon sampler. Where sample recovery is poor or nil,
a representative sample shall be preserved from the sludge
pump/bailer sample.
Whenever a sample recovery is recorded, the following details shall
Bidder 83 KDMC
and Drawings).
be noted along with usual record of blow counts. This information

shall be recorded for each borehole, in a format approved by the
Engineer in charge.
Ø Penetration and blow counts (meters)

Ø Recovery (meters)
Ø Logging of silt and fine sand, if any, observed.
Ø Description of soil sample.
In the case of stiff to medium clay where a sample is recovered in

the form of a "cake" a suitable length of cake shall be wraped with
a layer of bandage cloth and coated with paraffin wax to preserve
the sample.
The identification tag for the sample shall be carefully secured tothe
plastic container in which samples are preserved.
b) Field Vane Shear Test
Field Vane Shear Test shall be conducted as stipulated in the

relevant IS codes. During boring operation, when soft clay layers
are encountered the same shall be brought to the notice of the
Engineer in charge who shall decide whether Vane Shear Tests are
to be conducted in such strata.
Ø LABORATORY TESTING
All the specified laboratory tests shall be conducted in a nationally

accredited laboratory in consultation with the Engineer in charge.
Such laboratory should have recognition from the National
Highways Authority of India, Government of India. The relevant
Indian Standard Codes of Practices for Soil Testing shall be
followed.
For preparing the laboratory test schedule, a list of all soil an rock
core samples collected from each borehole shall be submitted to
the Engineer in charge with records of borelogs and in-situ tests in
duplicate. One of the copies shall be returned to the Contractor
indicating the tests to be conducted. All the consolidation and
permeability tests on collected samples shall be conducted at
laboratory of reputed institutes like IIT or as approved by the
Bidder 84 KDMC
and Drawings).
Engineer in charge. The results including plots and tables shall be

submitted along with the report. Test observations and calculations
shall be made available to the Engineer in charge if demanded.
* Preparation of Test Specimens

Preparation of test specimens for the various tests shall be carried
out as per the procedures laid down in the various relevant Codes
of Practice.
In case of soft to firm cohesive undisturbed soil samples, test

samples for all types of shear tests shall be prepared strictly by
hand trimming or soil lathe. Care shall be taken against bending of
soil samples at the time of horizontal ejection of the samples from
the sampling tubes. Samples shall be ejected from the sampling
tubes preferably in the same direction of travel in which the
samples entered the sampling tubes.
Similarly test specimens for consolidation tests shall also

beprepared to the required size by hand trimming only and the ring
ofthe consolidation apparatus shall be inserted by pressing
gentlywith the hands and carefully removing the material around
the ring. In no case the ring shall be forced into the soil. Great care
shall be taken during the trimming of the sample from the top and
thebottom of the ring. The test specimen shall be prepared in
thesame orientation as that of the actual strata so that the
laboratory test load compresses the soil in the same direction
relative to the soil strata as the applied load in the field.
* Index Property Tests

Laboratory tests shall be carried out in consultation with the
Engineer in charge and as per relevant parts of IS:2720 to find out
the following index properties:
Natural Moisture Content

Sieve and Hydrometer analyses
Atterberg Limits
Specific gravity
Bulk and Dry Density
The soil samples to be tested shall be selected by the Engineer in
charge.
Bidder 85 KDMC
and Drawings).
* Triaxial Test
Unconsolidated, undrained triaxial test shall be conducted on the
undisturbed samples selected by the Engineer in charge. The test
shall be conducted as per IS:2720 (Part X). Each test shall be
conducted on a minimum of three specimens at different cell
pressure (1.0, 2.0 and 3.0 kg/cm2).
The moisture content before and after the test and the bulk and dry
densities of each specimen shall be determined. The rate inserted
by the tenderer in the bill of quantities for the tri axial compression
test shall include for all the above items.
The stress-strain diagrams as well as the Mohr circle envelopes

shall be included in the report.
* Consolidation Test
Consolidation test shall be conducted on undisturbed samples as
per IS:2720 (Part XV) selected by the Engineer in charge. The
loading on the test specimens shall be applied in the following
stages : 0, 0.1, 0.25, 0.5,1.0, 2.0, 4.0, 8.0 kg/sq.cm Unloading of
the test specimens shall be done in suitable stages. The co-
efficient of consolidation (Cv), thecoefficient of volume
compressibility (Mv), compression index (Cc) and the coefficient of
permeability (k) shall be determined andreported.
* Unconfined Compression Test

Rock samples having L/D ratio not less than 2 shall be prepared
and tested under soaked condition for uniaxial crushing strength as
per IS:9143 and IS:9221.The stress-strain relationship and
modulus of elasticity shall also be reported. Bulk and dry densities,
porosity, water absorption, specific gravity shall also be determined
on rock samples as per IS:1124.
* Chemical Analysis
Chemical analysis of soil and water samples shall be carried out for
pH value, sulphate content (SO3) and chloride content (CI) in ppm
and percentage.
Bidder 86 KDMC
and Drawings).
3. CODES AND STANDARDS

All field and laboratory work shall be carried out strictly in accordance with
IS Codes of Practice and these specifications, unless otherwise approved
by the Engineer in charge in writing. In case of conflict, the IS Codes of
Practice shall prevail unless otherwise instructed in writing by the Engineer
in charge.
4. REPORTING REQUIREMENTS
The work includes the preparation and submission of an Investigation
Report containing plans showing the location of boreholes including
coordinates and levels, plans showing boreholes, project details and
description of work carried out, bore logs, corelogs, field test results and
laboratory test results. Report should also contain interpretation of test
results, recommendations for founding levels and bearing capacities,
potential settlements and ground improvement.
The recommendations shall especially cover the Foundation types,

founding levels and bearing capacity for the structures as identified in the
project description and as shown in the drawings. The foundation types
and founding levels shall be clearly identified.
Report shall also cover Safe Bearing Capacity and settlement analysis for
shallow foundations, retaining walls, pile capacity andground improvement
techniques.
The report shall include commends on aggressive chemical contentof soil

and groundwater and recommendations for deciding level of protection
necessary for concrete and steel buried parts.
Bidder 87 KDMC
and Drawings).
CLAUSE SP-10 :- ADDITIONAL SPECIFICATIONS FOR PROTECTIVE COATINGS

FOR CONCRETE
Description:- This work shall consist of the application of protective coating for
exposed concrete structures specified on the Drawings or the
preparation of surfaces, application and curing of the primer and
coating, protection of the work and furnishing all labour, equipment
and materials needed to perform the work.
Materials: - a) Coating on external surfaces of Deck / Girder / box.

The protective coating shall comprise of epoxy – henolic primer and
an intermediate coat of epoxy – phenolic interpenetrating polymer
network system and a top coat of interpenetrating polymer network
compatible polyurethane, the IPN system of CBRI Roorkee know-
how. The total dry film thickness shall not be less than 250 microns
and the system shall have the following properties.
Bond Strength with concrete, N/mm2: > 2.5
BS 3900-E-10-9
Tensile Strength, N/mm2: > 15
ASTM D-2370
Elongation %: > 15
ASTM D-2370
Water Vapour transmission, mg / cm2 / mm / 24 hr < 0.15 ASTM
D1653
UV – Resistance: Excellent
b) Coating on sub-structure exposed to atmosphere.

The coating shall comprise of two coats of aliphatic acrylic
solvented system having the following properties.
DFT:- 200 microns in 2 coats

Adhesion (ASTM-D-4541-6.01):- 30 kg / cm2 minimum
Water Vapour Permeants
(ASTM-D-1655):- Min 20 g/sq.m / day at 75% RH at 250C.
Water Penetration Test (Immersion Method):- Nil
Resistance to chloride:- Negligible Less than 10-7 cm2/sec.
Bidder 88 KDMC
and Drawings).
c) Coating on sub-structure in contact with earth, Coal tar

epoxy.
The coating shall consist of two coats of tar – extended epoxy

system of CECRI Karaikudi know-how having 300-350 microns in 2
coats and having following properties. Base Tar extended epoxy –
amine adduct Quick curing two component
Colour: - Black
Volume of Solids: - 80% (minimum) Drying time (touch
dry): - 2 hours
D.F.T. in two coats: - 300 – 350 microns
Chemical resistance: - Excellent against chlorides, salts,
sulphate, alkalies.
Salt spray test: - Should pass as per ASTM-B-117
1000
hrs minimum
Adhesion: - 3.8 KN minimum as per ASTM D
4541
Resistance Impedance: - 108
Surface preparation: - As per manufacturers specification or
as per relevant IS codes.
Coating System
d) Coating System 1) Coating on External surfaces of Deck / Girder / Box.

Interpenetrating polymer network system of CBRI Roorkee
know how system consists one coat of Epoxy Phenolic
primer of DFT 50 microns and one coat of Epoxy Phenolic
interpenetrating polymer network (IPN0 coating of DFT 100
microns and one coat of polyurethane of DFT 100 microns
IPN compatible system (Total DFT minimum 250 microns)
the IPN system of CBRI Roorkee Know-how or any other
epoxy coating system approved by the Engineer in charge.
The system shall have minimum 5 years field experience in
Indian conditions.
2) Coating on sub-structure exposed to atmosphere.
Two coats each of 100 microns DFT (Total 20 microns) of

Aliphatic Acrylate based solvented waterproof, anti-fungal
coating system or any other equivalent coating system
approved by the Engineer in charge. The system shall have
minimum 5 years field experience in Indian conditions.
Bidder 89 KDMC
and Drawings).
3) Coating on substructure in contact with earth.
Applying two coats of coal tar epoxy system each coat of

DFT 150 microns each (Total minimum DFT 300 microns)
as per Central Electro chemical Research Institute
Karaikudi system. The system shall have minimum 5 years
field experience in Indian conditions.
4) Coating on inside of P.S.C. Box girder
Internal concrete surface of box girder shall be painted with

three coats of cement-based paint approved by the
Engineer in charge.
Construction
Requirements All surfaces shall be dry and free from contamination such
as oil, grease, loose particles, decayed matter, laitance, all
traces of mould release oils and curing compounds. Where
application over existing coatings is required, trials shall be
conducted to ensure compatibilityand retention of bond
between the underlying coating and thesubstrate.
It is essential to produce an unbroken coating of the

material. Surfaces containing blow holes or similar areas of
pitting shall first be filled using a cementitious fairing coat
and allowed to cure for 48 hours before application of the
coating material. Minimum application rates and over
coating times are to be observed: as per manufacturer’s
recommendations or as approved by the Engineer in charge
Storage and
Precautions The primer shall be allowed to dry for a minimum of 12
hours at 200Cor longer at lower temperatures, before
application of the coating. Under no circumstances shall the
primer be over coated until the surface is properly dry.
All products shall have a shelf life of at least 12 months. It
shall be stored in cool, dry conditions, away from sources of
heat and flames, inthe original unopened packs.
Precautions must be observed during the use of the system
in a ccordance with the manufacturer’s recommendations.
Bidder 90 KDMC
and Drawings).
CLAUSE SP-11 SPECIFICATION FOR PRECAST CONCRETE SEGMENTAL

CONSTRUCTION
PART 1-GENERAL
1.01 DESCRIPTION: - This document includes Special Provisions for the furnishing
and installing of precast concrete segments into the bridge superstructure.
1.02 DEFINITIONS
A. Segment refers to a modular section of the superstructure. The cross-
section, length, and details of the segments are as shown in the Design
Drawings.
B. Match Cast refers to a precast concrete fabrication procedure whereby a
segment is cast against the preceding segment thereby producing a
matching interface that will permit reestablishment of the cast geometry at
the time of erection. Match casting may be accomplished by either the
short-line casting method or the long-line casting method.
C. Short-line Casting is the method of casting segments one at a time on a
casting bed utilizing a fixed or movable bulk head. The first segment is cast
between bulkheads, and successive segments are cast, one at a time,
against the bulk head on one end and the repositioned, previously cast
segment onthe other end.
D. Balanced Cantilever Erection is a method by which the segments are
sequentially placed, in cantilever, alternately on either side of the pier to
apoint where a closure joint is cast in place.
E. Camber is the amount by which the concrete profile at the time of casting
must differ from the theoretical geometric profile grade in order to
compensate for all structural dead-load, post-tensioning, long-term and
time-dependent deformations (creep and shrinkage), including gg the
intermediate erection stages and effects.
F. Castin Curve: is the curve of casting geometry that is followed at the
casting gg bed to achieve the theoretical profile after final deformations
have taken place. The casting curve is developed by integrating theoretical
profile and camber.
G. Erection Elevations are the elevations to which segment joints should be
located at each stage of erection in order for the bridge deck to match the
theoretical roadway profile after construction and after all long-term
deadload deflections have occurred.
H. Shop Drawings are documents prepared from the information shown on
the Design Drawings which provide details necessary for the construction
of the work. “Shop Drawings” is a general term that includes drawings,
diagrams, illustrations, samples, schedules, calculations, and other data.
The precast segments shop drawings are drawings that are clearly
detailed to show the relationship between reinforcing bars, post-tensioning
Bidder 91 KDMC
and Drawings).
hardware, and allother embedded items in an attempt to avoid

interferences between these elements.
I. Casting Manual: is a manual for the casting and the geometry control of
the precast segments prepared by the Contractor and/or the Construction
Engineer in accordance with the information provided in the Design
Drawings, the Shop Drawings and these Special Provisions.
J. Erection Manual: is a manual for the detailed step-by-step erection of the
precast segments including all intermediate procedures relating to any
erection equipment, falsework, counter weights, post-tensioning,
placementor removal of temporary supports, closure operations. The
manual also includes theoretical erection elevations at each stage of
erection, and survey monitoring procedures.
K. Designer: is the firm or organization responsible for the detailed design of
the bridge.
L. Engineer in charge: is the firm or organization responsible for acceptance
of the completed structure.
M. Construction Engineer: is the individual or firm hired by the Contract or
responsible for carrying out specialized engineering services required to
construct the bridge in accordance with the Contract Documents.
N. Standard Specifications: Standard material specifications conforming to
MoRTH specifications or equivalent Indian Standards, British Standards,
AASHTO, ASTM as applicable.
1.03 REFERENCES
A. American Society for Testing and Materials (ASTM):
ASTM A 53 Standard Specification for Pipe Steel, Black and Hot
Dipped,Zinc Coated, Welded and Seamless
ASTM A 416 Standard Specification for Steel Strand
ASTM A615 Standard Specification for Deformed and Plain Billet-Steel

Bars for Concrete Reinforcement
ASTM A 653 Standard Specification for Steel Sheet, Zinc-Coated

(Galvanized) orZinc-Coated Alloy-Coated (Galvannealed)
by the Hot Dip Process
ASTM A-722 Standard Specification for Uncoated High-Strength Steel
Bar for Prestressing Concrete
Bidder 92 KDMC
and Drawings).
ASTM C109 Standard Test Method for Compressive Strength of

HydraulicCement Mortars (Using Two-Inch or (50 mm)
CubeSpecimens)
ASTM C469 Test Method for Static Modulus of Elasticity and

Poisson’sRatio of Concrete in Compression
ASTM C512 Standard Test Method for Creep of Concrete in

Compression ASTMC827 Standard Specification for
Chemical-Resistant Sulfur Mortar ASTM C-939 Standard
Test Method for Flow of Grout for Preplaced-
Aggregate Concrete (Flow Cone Method)
ASTM C-940 Standard Test Method for Expansion and Bleeding of

FreshlyMixed Grouts for Preplaced-Aggregate Concrete in
theLaboratory
ASTM C-942 Standard Test Method for Compressive Strength of Grouts
for Preplaced-Aggregate Concrete in the Laboratory
ASTM C-953 Standard Test Method for Time of Setting of Grout for
Preplaced-Aggregate Concrete in the Laboratory
ASTM C-1152 Standard Test Method for Acid Soluble Chloride in Mortar
And Concrete
ASTM D-6690 Standard Specification for Joint and Crack Sealants, Hot
Applied for Concrete and Asphalt Pavements
B. American Association of State Highway and Transportation Officials
(AASHTO)
AASHTO M 45 Aggregates for Masonry Mortar

AASHTO M 85 Portland Cement
AASHTO M 148 Liquid Membrane-Forming Compounds for Curing Concrete
AASHTO M 235 Epoxy Resine Adhesives
AASHTO T 22 Compressive Strength of Cylindrical Concrete Specimens
AASHTO T 23 Making and Curing Concrete Test Specimens in the Field
C. Comité Euro-International du Béton-Fédération Internationale de la

Précontrainte (CEBFIP)
Model Code for Concrete Structures
Bidder 93 KDMC
and Drawings).
1.04 SUBMITTALS
The following engineering submittals shall be submitted for review by the
Engineer:
A. Shop Drawings: The Contractor shall prepare shop drawings for the
precast segments:
1. Fully and accurately dimensioned views showing the geometry of
Each segment including projections, recesses, notches, openings,
and blockouts.
2. Fully integrated drawings showing reinforcing steel, pre tension in
strand post-tensioning ducts, post-tensioning hardware, inserts,
lifting
Devices and all other items to be embedded in a segment. Details
of mild steel reinforcing shall clearly indicate size, spacing, and
location including all anchorage reinforcing not shown in the Design
Drawings that may be required by the post-tensioning anchorage
system selected by the Contractor. Details of post-tensioning gg
ducts shall clearly indicatethe size, type, horizontal and vertical
profiles, duct supports, groutpipes, and concrete cover. The
Contractor shall review these drawings to verify dimensions,
accuracy, conflicts, and completeness. Conflicts shall be called to
the attention of the Designer. Each segment shall be assigned an
erection mark indicating its location and order in the erection
sequence.
B. Casting Manual
1) The Contractor shall prepare a Casting Manual for the casting and
geometry control of the segments.
2) Casting curves shall be prepared and submitted by the Contractor
in accordance with the casting and erection methods, schedule,
loads, and material properties proposed by the Contractor. The
casting curves shall be of sufficient accuracy to allow the
determination of control point settings while casting the segments.
The casting curves shall bebased on the final theoretical bridge
geometry as modified by the camber curves prepared by the
Designer. Each casting curve submittal shall be accompanied by all
information (loads, casting and erection schedules, and material
properties) considered in its development. The preparation of
casting curves is dependent upon the erection sequenceand the
Contractor's schedule. Therefore, if the Contractor proposes a
change to a previously approved erection procedure, the
Contractor shall develop a new casting curve in the same manner
as required forthe original casting curve. The Contractor shall
Bidder 94 KDMC
and Drawings).
develop the method(s)and location(s) for transitioning between the

approved curve(s) in use and the submitted curve(s). The
Contractor shall prepare a casting manual for the casting and
geometry control procedures in accordance with the information
provided in the Design Drawings and these Special Provisions.
C. Handling, Storage, and Transport of Precast Segments
1. The Contractor shall develop complete details of handling, storing, and
transporting segments. These details shall include, for each type of
segment, the method of lifting, location of all penetrations or liftin inserts,
configuration of lifting devices, the method of supporting segments during
storage and transportation, the planned route for transporting the
segments, and the axle loads for the segment hauler.The details shall be
accompanied by calculations indicating that the forces imposed on a
segment during lifting, storage, and transportation will not adversely affect
the structural adequacy of the segment.
2. In case the Contractor decides to double stack the segments, special
bracings will be required to prevent damage in the lower segment.
D. Erection Manual
1. The Contractor shall prepare an Erection Manual for the detailed step by-
step erection of the segments including all intermediate procedures
relating to all erection equipment, falsework, movement of equipment,
jacking procedures at closure joints, stressing of temporary post-tensioning
bars, closure operations including any partial stressing across the closure
during concrete curing, location and size of shimblocks, main post-
tensioning tendons stressing sequences, jacking forces and elongations,
erection elevations, the field survey, alignment methods, alignment control
methods to be employed for setting the initial and subsequent segments,
and all other relevant operations. This manual will use the information
provided by the Designer for post-tensioning tendons stressing and
intermediate cantilever deflections during erection.
2. The Erection Manual shall include the sequence in which the segments are
to be erected and a table of theoretical elevations and alignment of the
geometry control points established during the casting of each segment
computed at each stage of erection. Stages for which theoretical positions
of control points are to be computed shall include segment in place prior
to applying permanent post-tensioning and The segment in place with
post-tensioning applied.
3. The theoretical position for the control points shall be computed taking into
consideration:
a.) The effect of as-cast geometry established from surveys conducted
during casting of the segments.
b.) Effects of construction dead and live load. c.) Effects of post-
tensioning.
Bidder 95 KDMC
and Drawings).
d.) Effects of creep and shrinkage. Deformation due to creep and

shrinkage and the concrete modulus of elasticity shall be computed
using the recommendations of the 1990 CEB-FIPModel Code for
Concrete Structures.
e.) The final profile of the roadway as shown in the Design Drawings.
4. The procedure shall also include a method for measuring and recording
the elevations and alignment of all control points at each stage of erection.
5. The Contractor shall prepare a new erection procedure for submittal each
time he proposes to deviate from the sequence of erection contained in the
approved erection procedure under which he is operating.
E. Construction Equipment:
The Contractor shall develop complete details covering equipment to be
used to handle segments and incorporate them into the structure, erection
methods to be used, the sequence of erection, all loads to be imposed on
portions of the permanent structure by the erection equipment, and details
covering the procedures for load testing of erection equipment. T
eConstruction Engineer shall verify that these loads do not adversely affect
the structural integrity of permanent structure, or shall design the
necessary measures to reinforce the permanent structure.
F. Load Testing:
The Contractor shall submit calculations supporting the construction
equipment load test specified in these Special Provisions.
1.05 QUALITY ASSURANCE

Qualifications of Contractor's Personnel: The Contractor shall provide various
engineering, field supervision, and technician level functions required in order to
meet requirements of these Special Provisions. In particular, the Contractor shall
supply the following personnel:
1. Construction Engineer
a.) The Construction Engineer a Professional Engineer who has
specific knowledge of and experience in design and construction of
precast concrete segmental bridges erected using balanced-
cantilever techniques.
Bidder 96 KDMC
and Drawings).
b.) The Construction Engineer shall be responsible for carrying

out specialized engineering services required to construct the
bridge in accordance with the Design/Build Contract requirements
and these Special Provisions.
2. Geometry Control Technician

a.) The Contractor's personnel responsible for carrying out geometry control
activities during casting of the concrete superstructure segments and
during erection of these segments, shall be trained in the use of the
geometry control software, survey control, and data collection requiredy
the Construction Engineer and for permanent record. Training may be
conducted on site under the supervision of personnel that possess skills
and prior experience in the specific type of work necessary to effectively
control the final geometry of the bridge superstructure.
b.) Prior to beginning work that requires geometry control measurements, the
Contractor shall submit for review by the Engineer complete information
establishing control activities. Only technicians whose qualifications have
been reviewed by the Engineer shall be assigned to carry out geometry
control activities.
The Contractor's geometry control technicians shall carry out all geometry
control in the casting yard and during erection of the bridge superstructure
as required by these Special Provisions.
3. Post-Tensioning Superintendent
All post-tensioning field operations shall be performed under the direct supervision
of a superintendent employed by the Contractor. The superintendent shall have a
minimum of 5 years of general bridge construction experience, of which 2 years
must have been in post-tensioning operations.
Bidder 97 KDMC
and Drawings).
PART 2 -PRODUCTS
2.01 MATERIALS
A. Reinforcing Steel shall comply with the requirements of the Standard
Specifications. Field welding of reinforcing steel shall not be permitted, except at
locations designated in the Design Drawings.
B. Portland Cement Concrete shall comply with the requirements of the Standard
Specifications, Gradation of coarse aggregate utilized in the concrete for precast
segments shall take into account reinforcing bar spacings shown in the Design
Drawings. Screenings shall not be permitted as substitute for silica sand for use in
concrete of precast segments. The 28 day concrete strength shall be as shown in
the Design Drawings. Minimum concrete strengths to permit match-casting, form
removal, handling, and stressing shall be in accordance with the requirements
shown in the Design Drawings.
The Contractor shall submit for approval by the Engineer in charge all concrete
mix designs prior to use. Submittal shall include performance history, mix
proportions, material sources, aggregate gradations, and other requirements of
the Design/Build Contract and these Special Provisions.
C. Epoxy for Segment Joints
The epoxy material shall be in accordance with AASHTO Materials
Specification M235.
D. Post tensioning materials
The post-tensioning materials shall comply with the requirements of the
Special Provisions for Post-Tensioning.
Bidder 98 KDMC
and Drawings).
2.02 FABRICATION
D. Casting Concrete
1. General
All materials, details, and procedures shall be as specified herein or noted
on the Design Drawings. Casting of segments shall not begin until the
review of shop drawings, required computations, post-tensioning system,
and concrete mix design, has been completed and approved by the
Engineer in charge. The segments shall be match cast.
2. Design of Forms
a.) The design and engineering of forms, as well as their construction, shall be the
responsibility of the Contractor. Forms shall be inspected and approved by the
Engineer in charge prior to authorizing casting operations. Forms that are worn,
damaged, or otherwise unacceptable to the Engineer shall be repaired to the
Engineer's satisfaction before the casting of segments will be authorized. Forms
that do not produce segments complying with specified casting tolerances shall
not be used until corrections are made.
b.) Forms shall be mortar tight and sufficiently rigid to prevent distortion due to
pressure of concrete and other loads incidental to concrete operations, including
vibration. Forms shall be capable of casting segments as shown in the Design
Drawings, adjusting to changes in segmental geometry as shown in the Design
Drawings and correcting previous minor casting errors, stripping without damage
to the concrete, providing a tight, leak-proof joining to the previous segment,
holding post-tensioning ducts at the correct location without intrusion of grout.
c.) All exposed surfaces of each element of the structure shall beformed with
materials that produce a similar surface texture, color, and appearance for all
concrete surfaces. The form surfaces of casting machines for superstructure shall
be made of steel. The metal used for forms shall be of such thickness that the
forms will remain true to shape. All bolt and rivet heads in contact with concrete
shall be countersunk. Clamps, pins, or other connecting devices shall be designed
to hold the forms rigidly together and to allow form removal without injury to the
concrete.
d.) The inside surfaces of forms shall be cleaned of all dirt, mortar, and foreign
material. Forms shall be properly coated with form oil prior to each use. The form
oil or other equivalent bond breaking coating shall permit ready release of forms
and shall not discolor the concrete. Form oil shall be applied such that none is
deposited on reinforcement in the forms. Where sections of forms are to be joined,
a maximum offset of 1.5 mm for flat surfaces and 3 mm for corners and bends will
be permitted.
e.) The Contractor shall accurately survey forms on a periodic basis for the purpose
of monitoring settlements and distortion in shape. If settlements or distortions are
of sufficient magnitude to interfere with achieving required segment tolerances,
casting withthese forms shall be discontinued until the problem is corrected.
Bidder 99 KDMC
and Drawings).
3. Preparation for Casting

a.) Care shall be exercised in setting up forms for casting segments. All materials to
be encased within the concrete of the segment shall be properly positioned and
supported. Provisions for all projections, recesses, notches, openings, block-outs,
and the like shall be made accordance with approved shop drawings. Extreme
care shall be taken positioning the match-cast segment in relation to the segment
to be poured. The match-cast segment shall not be subjected to a stress inducing
twist. The abutting surface of the bulk head segment shall becovered with a thin
film of a bond breaker consisting of flax soap and talc, or other material approved
by the Engineer in charge. The soap and talc mixture will be approximately five
parts flax soa and one part talc. The mixture may be varied based on job
experience and results. The acceptability of a material other than soap and talc
shall be determined by demonstration on a large specimen with a facial area of at
least 900 square cm prior to its use in casting of segments.
4. Geometry Control
a.) General
(1) Before commencing the casting operation, the Contractor shall submit tothe
Engineer, for approval, his proposed method of geometry controlsor both casting
and erection operations. This submittal shall be in form of a "Casting Manual" and
shall include, but not be limited to, the following information: a detailed narrative of
the geometry control theory a detailed narrative of the step-by-step geometry
control procedure, detailed calculation forms, and a set of sample calculations.
This submittal shall include all measuring equipment, procedures, the locations of
the control points to be established on each segment, and the qualifications
ortraining program of personnel who will carry out geometry control.
(2) The casting manual shall cover all geometry control operations necessary for
casting and shall be in agreement with the Contractor's chosen methods of
casting and erection, including erection survey, elevation, and alignment control.
Casting shall not commence without the Engineer in charge's approval of the
geometry control method.
(3) Instruments used in the casting yard for horizontal geometry control shall be
mounted on a permanent platform independent of other structures. Provisions
shall be made to protect instruments from construction activities and to minimize
effects of wind and temperature variations on accuracy of readings.
(4) A minimum of two permanent horizontal control points shall be established on line
with the instrument mounting point. Permanent bench marks shall be established
at locations where they will not be disturbed by construction activities. The
horizontal control points and benchmarks shall be located so as to be
continuously visible from the instrument's location.
Bidder 100 KDMC

and Drawings).
(5) Prior to beginning casting operations using the short-line method, horizontal and
elevation control points shall be established on the fixed bulkhead. The alignment,
elevations, and shape of the fixed bulkhead shall be checked by taking readings
on these control points each time the geometry of adjoining segments is checked.
(6) Immediately after casting of a segment is completed, the length ofthe segment
along the line of each web shall be measured and recorded and references for
horizontal and vertical control shall be established as follows:
(i) Horizontal Control -A wire stirrup shall be set onthe horizontal control line at
both ends of the segment. A line not more than 0.3 mm in width shall be scribed in
apermanent manner into each stirrup. Wire stirrups shall be stainless steel.
(ii) Vertical Control -A flat head bolt, with a pin hole in the head, approximately
flush with the surface of the concrete over each web at both ends of the segment.
Bolts shall be stainless steel.
(iii) After a segment is cast, and before bond breaking, positions of the two
adjoining segments shall be checked from established control points. If positions
are not as required, corrections to the geometry shall be made in the next
segmentcast utilizing established control points.
b.) Requirements for Short-Line Casting of Bridge superstructure

Segments
(1) Elevation and centerline-offset measurements shall be observed to an
accuracy of ±.0.3 mm.
(2) The setup position of two adjacent segments before casting shall be
independently determined by two observers. Casting shall not begin until
these surveys agree within thefollowing tolerances.
Elevation: ±0.6 mm on control points
Horizontal: ±0.6 mm on a segment centerline offset
(3) After-cast observations shall be independently determinedby two observers.
They shall be checked until independent observations agree within the
following tolerances:
Elevation: ±0.3 mm on control points
Horizontal: ±0.3 mm on a segment centerline offset
Twist error on elevation control points: ±0.3 mm (with ±0.6mm maximum
on a random error)
5. Embedded Items
a.) Reinforcing steel shall be fabricated and placed in accordance with the
Design Drawings and as required herein. No reinforcing steel shall be cut
or removed to permit proper alignment of tendon ducts or other embedded
items without approval of the Engineer in charge. Bars that cannot be
fabricated to clear a post-tensioning tendon shall be replaced by additional
bars with adequate lap lengths using a method approved by the Engineer
in charge. In the plane of the steel parallel to the nearest surface of
Bidder 101 KDMC

and Drawings).
concrete, bars shall not vary from plan placement by more than 12 mm, or
1/12 of the spacing between bars, whichever is less. In the plane of the
steel perpendicular to the nearest surface of concrete, bars shall not vary
from plan placement by more than 6 mm. The top and bottom clear cover
of reinforcing steel shall be within 6 mm of the clear cover limits
dimensioned on the Design Drawings, except for the top deck for which the
clear cover shall be within -0 to12 mm. The end and edge clear cover of
the reinforcing steel shall be within 25 mm of the clear cover limits
dimensioned on the Design Drawings.
b.) Reinforcing bar fabrication shall be in accordance with the applicable

recommendations of the Concrete Reinforcing Steel Institute (CRSI)
Manual of Standard Practice, Design Drawingr equirements, and to the
tolerances specified above. In the event of a conflict between post-
tensioning hardware and reinforcing steel, the post-tensioning shall
generally have priority and the reinforcing steel shall be adjusted as
approved by the Engineer in charge.
c.) Embedded ducts for tendons shall be positioned accurately (within 6 mm)
in respect to their vertical, linear, and transverse position within each
segment. Positive methods shall be utilized to ensure that ducts will not be
displaced during casting. Mandrels shall be used as stiffeners in each duct
and shall extend throughout the length of the segment being cast and at
least 600 mm into the corresponding duct of the previously cast segment.
The mandrels shall be of sufficient rigidity to maintain the duct geometry
within the specified tolerances in the segment webs, top and bottom
flanges, and within 3 mm tolerance at the segment joints. The ducts shall
be connected with watertight duct couplers at the segment joints. The
Contractor shall submit to the Engineer in charge, for approval,the method
roposed to align ducts passing from cast-in-place concrete into precast
units.
d.) Methods of support and spacing of supports for ducts shall be shown on
the shop drawings. After installation in the forms, the end of the ducts shall
be sealed at all times to prevent entry of water and debris.
Following each pour of concrete, the Contractor shall verify that all empty
ducts are free of water and are unobstructed and undamaged. Immediately
prior to installation of the prestressing steel, the Contractor shall again
verify that all ducts are unobstructed and that they are free of water and
debris.
Bidder 102 KDMC

and Drawings).
e.) If cast-in-place lifting devices are used to handle the segments, the lifting
devices incorporated in superstructure segments shall be adequate to
distribute the handling and erection stresses so as to not damage the
segment. If penetrations in the top slab of the segment are used to handle
the segments, the location, size, andshape of the penetration shall be
submitted to the Engineer in charge for approval.
f.) The anchoring devices for transverse top slab post-tensioning shall be
recessed so that the ends of the prestressing steel and all parts of
anchoring devices will be at least 50 mm inside the endsurface of the
segment. Following post-tensioning, the recesses shallbe filled in
accordance with the details noted on the DesignDrawings.
g.) Transverse post-tensioning anchors shall be placed into the form before
the concrete is cast. Temporary block-outs for anchors will not be allowed.
B. Placing Concrete
1. Concrete shall not be deposited into forms until the entire setup of the forms,
reinforcements, ducts, and anchorage has been thoroughly inspected and
checked. The placing of concrete will not be permitted until the Engineer in charge
is satisfied that the rate of producing and placing concrete will be sufficient to
complete the proposed pour and finishing operations within the scheduled time,
that experienced concrete finishers are available where required, and all
necessary finishing tools and equipmentare on hand at the site of the work and
are in satisfactory condition for use.
2. During conveying, placement, and initial set, the concrete shall be protected
against undue drying or rise in temperature and inclement weather. The placing of
concrete will also not be permitted until the Engineer in charge is satisfied that
adequate measures, and protection, are available to prevent weather damage
during conveying and placement.
3. Special care shall be taken to plan the sequence of placing concrete so asto as
sure that voids do not occur within the concrete in areas where air is likely to be
entrapped within the forms or in areas where flow of the plastic concrete is
constrained by embedded items. Concrete shall not be dropped more than 1.5 m,
unless confined by closed chutes or pipes. Care shall be taken to fill each part of
the form by depositing the concrete as near final position as possible.
Concrete shall be placed in horizontal layers not more than 450 mm. Eachlayer
shall be so consolidated as to avoid the formation of a construction joint with a
preceding layer.
Immediately after the work of placing concrete has been completed, all
accumulations of mortar on the exposed reinforcement and surfaces of
Bidder 103 KDMC

and Drawings).
forms shall be removed before the concrete takes its initial set. Care shall
be taken when cleaning reinforcing steel to prevent damage to or
breakage of the concrete-steel bond.
Placing equipment shall be of a size and design that will permit the placing
of concrete within the time limits set in the Standard Specifications.
Placing equipment shall be cleaned as necessary at the end of each

operation or workday and, just prior to reuse, shall again be checked and
cleaned of hardened concrete and foreign materials. Belt conveyors shall
be horizontal or at a slope that will not cause excessive segregation or loss
of ingredients. Concrete shall be protected against undue drying or rise in
temperature. An approved device shall be used at the end of a belt
conveyor to prevent aggregate segregation. Mortar shall not be allowed to
adhere to the return length of thebelt. Concrete shall be discharged into a
hopper or through a baffle. No construction joints will be permitted within a
segment exceptas detailed on the Design Drawings.
C. Tolerances
1. The following tolerances shall apply to the fabrication of superstructure segments:
Width of web ±8mm
Depth of bottom slab ± 8mm
Depth of top slab ± 8 mm
Overall depth of segment ±10 mm
Overall width of top slab ± 20 mm
Overall width of bottom slab ± 15mm
Length of segment ± 15 mm, max. +50 mm per cantilever
Diaphragm dimensions ± 15 mm
Tendon Hole Location ± 3 mm
Shear Key Location ±6 mm
2. Dimensions from segment to segment shall be adjusted so as to compensate for

deviations within a single segment so the overall men ons of the completed
structure will confirm to the dimensions shown on the Design Drawings.
3. The maximum differential offset between outside faces of adjacent segments in
the erected position shall not exceed 6 mm.
4. Transversely, the completed segments shall not deviate from the theoretical cross
slope of the roadway by more than 0.001radians, measured curb-to-curb.
5. Longitudinally, the angular deviation from the theoretical slope change between
two successive segments shall not exceed 0.003radians.
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and Drawings).
D. Vibration
All concrete shall be consolidated by means of approved vibrators together with all
other equipment necessary to perform the work as specified. Internal vibrators
shall have a minimum frequency of 8,000 vibrations per minute and sufficient
amplitude to consolidate the concrete effectively. At least two standby vibrators in
working conditionshall be provided for emergency use in case of malfunction. The
use of external vibrators for consolidating concrete will be permitted and may be
required when the concrete is in accessible for adequate consolidation. When
external vibration is used, the forms shall be constructed sufficiently rigid to resist
displacement or damage. Vibrating of concrete shall be done with care and in
such a manner as to avoid displacement of reinforcing, ducts, and other
embedded items.
E. Post Tensioning
1. The Contractor shall install the longitudinal and transverse post-tensioning ducts,
anchorages, grout vents, and other requireditems to the vertical and longitudinal
dimensions shown on the shop drawings. The Contractor shall cut, install, stress,
grout, and provide anchorage protection for all transverse post tensioning tendons
as called for in the Design Drawings and Special Provisions.
2. The post tensioning and grouting operations shall follow the requirements of the
Special Provisions for Post-Tensioning.
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and Drawings).
3. When steam curing is used, the steel for post tensioning shall not be
installed until the steam curing is completed, unless the anchorage systems
mandate its installation. Such tendons shall be protected against corrosion by
means of a corrosion inhibitor placed in the ducts or on the steel or shall be
stressed and grouted within 7 days after steam curing.
4. The transverse post tensioning ducts, in their final position, shall be placed
with a tolerance of +/-6 mm. They shall be securely tied in position and supported
at intervals not exceeding 600 mm to revent movement, displacement, or damage
from concrete placement and consolidation operations
5. The transverse post tensioning anchorages shall be protected in
accordance with the Special Provisions for Post Tension in within 20 days
following completion of the stressing and grouting operations.
F. Removal of Forms -Separation of Match-Cast Segments
1. Weight supporting forms shall remain in place until the concretehas
reached the compressive strength specified in the Design Drawings for
form removal, and the transverse post-tensioning tendons have been
stressed as required in the Design Drawings.
2. Care shall be exercised in removing the forms to prevent spalling and
chipping of the concrete.
3. The Contractor shall provide equipment to be used for uniform separation
of match-cast segments without damage.
4. Prior to moving a segment from its match-cast position, erection marks
identifying its location in the structure and order in the erection sequence
shall be affixed to the inside of the segment.
G. Test Samples
1. Test samples shall comply with the requirements of the Standard
Specifications. Additional test samples and testing for compressive strength shall
be made on each precast segment by the Contractor to control the construction
activities and to ensure adequate strength of these segments at various stages of
their manufacture and assembly. The Contractor shall make test cylinders from
concrete representative of that used to cast the segment, cured in the same
manner as the segments to ensure adequate compressive strength has been
achieved in accordance with the Design
Drawing requirements for the following conditions:
a.) Prior to form release, segment lifting and moving to storage.
b.) Prior to placing a segment into position in the structure and/or
stressing of post-tensioning tendons if the component is less than
28 days old.
2. The test specimens for precast segments shall be stored in accordance
with the requirements of the Standard Specifications.The Contractor shall
provide sufficient specimens to allow for additional tests, as required.
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and Drawings).
3. Modulus of Elasticity Tests: Tests shall be performed inaccordance with

the requirements of ASTM C469. Ages of specimens (cylinders) at time of
testing shall be 3, 28, and 90 days. The number of specimens per test
shall be three cylinders or a total of nine cylinders. All specimens in a given
sample shall be taken from the same batch of concrete.
4. Creep and Shrinkage Tests: Tests shall be performed in accordance with
the requirements of ASTM C512. Ages of specimens (cylinders) at time of
initial loading shall be 3, 28 and 90days. Specimens shall be cured and
stored in accordance with thestandard curing requirements of Section 6.1
of ASTM C512, except that the specimens shall be moist cured for a
period of 14 days or until age of test, whichever comes first. Thereafter,
specimens shall be stored at 23 degrees C and 50 percent humidity.
H. Finishing
1. Finishes of all exposed box girder exterior surfaces shall result into a uniform
appearance. Finishing of the riding surface shall take into account the
requirements for installation of the roadway surfacing.
2. Additional requirements for finishing the top surface of the precast segments: As
soon as the concrete has been placed and vibrated in a section of sufficient width
to permit working, the surface shall be approximately leveled, struck off and
screened such that a slight excess of concrete is carried ahead of the screed to
insure filling of the low spots. The screed shall be designed rigid enough to hold
true in shape. A hydraulically driven, bare steel tube rotating in the opposite
directionof travel may be used if heavy enough to prevent undue distortion.
The longitudinal screed shall be moved back and forth across the concrete while
one end rests on the upper surface of the form (bulkhead)and the other end on
the match-cast segment. The surface of the concrete shall be screened a
sufficient number of times, and at such intervals to produce a uniform surface, true
to grade and free of voids. The screened surface shall be worked to a smooth
finish with a long-handled wood or metal float of the proper size, or hand floated
from bridges over the top slab.
A straight edge, at least 600 mm longer than the segment, shall be used
approximately parallel to the centerline of the segment to strike an accurate
surface between the form bulkhead and the top of the previously cast segment at
all the positions across the segment width. All surface irregularities in excess of 3
mm indicated by straight edging shall be corrected while the concrete is still in the
plastic state.
I. Curing
1. General: curing procedures shall conform to the requirements the
Standard Specifications.
2. Additional requirements:
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and Drawings).
a.) To prevent moisture loss, all exposed surfaces (those not in contact with a
form or match-cast segment) shall be covered as soon as possible after
casting with a moisture-tight covering (wet curing blankets or other
approved equal system). Care shall be taken to avoid spoiling the deck
surface finish. The covering may be kept on or within 1-foot of the deck
surface.
b.) The moisture-tight cover in shall remain substantially inplace throughout
succeeding operations such as geometry control survey, stripping of
internal forms, wing forms, and shifting of and working with a segment in a
match-cast position.
c.) After stripping of the side and core forms, curing of the precast concrete
shall continue by the application of a membrane curing compound to all
exposed surfaces (including segment exterior once exposed by removal
from the form). Match-cast surfaces shall have an approved de-bonding
compound applied to serve both as bond breaker and seal for curing.
d.) The moisture-tight covering shall be maintained for at least 72 hours.
e.) For the period in which the new-cast segment is in contact with the match-
cast segment, the latter shall also be covered with curing blankets, or other
approved equal system, to minimize the effects of differential temperature
between the segments.
f.) The application of the membrane curing compound shall not result in a
non-uniform appearance from one segment to the next. In consistencies in
segment appearance shall be corrected by the Contractor with no
additional compensation.
3. Accelerated Curing with Low Pressure Steam or Radiant Heat:

When accelerated curing has to be used in order to achieve the daily casting
cycle, the match-cast segment shall be exposed to the same curing environment
(temperature and humidity) as the segment being cured with low pressure heat or
radiant heat. Membrane curing will not be required in addition to steam curing.
J. Precast Segment Handling, Storage, and Shipment

1. General
a.) Care shall be exercised in the handling of segments top revent damage to
them. Handling shall be done using only the devices shown on the
approved shop drawings for this purpose. Lifting devices shall be adequate
to distribute handling and erection stresses so as not to damage the
segment.
b.) The Contractor shall inspect each segment visually for evidence of
damage or defect before, during, and after critical operations and as often
as necessary to ensure adequate equality control.
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and Drawings).
c.) Superstructure segments shall be stored level in the deck upright position
and shall be firmly supported in a manner that does not introduce “twist” in
the segment, at the locations shown on the shop drawings. The storage
area of the segments shall be of suitable stability to preventdifferential
settlement of the segment supports, whichresults in an unstable storage
condition during the entireperiod of storage.
d.) Prior to shipment, each segment shall be inspected for damage. The faces
of all match-cast joints shall be thoroughly cleaned of laitance, bond
breaking compound, and all other foreign material by wire brushing or
lights and blasting. The Contractor shall also demonstrate to the Engineer
in charge that all empty ducts are free of mortar and water, and are
unobstructed and undamaged. During transport, firm support at the
bearing locations noted above for support during storage shall be provided
and the segments shall befully secured against shifting. Upon arrival at the
erection sight, each segment shall again be inspected.
2. Damaged or Defective Segments
a.) Isolated defects are defects or damage that occurs randomly and in
frequently, as determined by the Engineer.
b.) Recurring defects are defects or damages of the same enera type and
nature that continue to be found in the same general location of the
segments at an unacceptable frequency, as determined by the Engineer in
charge.
c.) As a minimum, the first five segments cast will be jointly inspected by the
Contractor and the Engineer in charge after casting, after moving to
storage from the casting machine,an before erection. All segment defects
shall be identified and categorized during this inspection. The Contractor
shall examine the defects and propose to the Engineer in writing:
(1) The measures the Contractor shall take to prevent recurring
defects in future segments.
(2) The method of repair of all defects discovered as a result of the
inspection as required herein.
d.) The Engineer will determine what constitutes damage or defect, whether
the damage or defect is isolated or recurring, and will categorize the
damage or defects. Three categories of defects are considered for this
purpose:
(1) Cosmetic: Cosmetic defects or damages are those that do not
affect the ability of the segment to resist construction or service
loads or reduce the life expectancy of the structure. This category
of defect includes a superficial discontinuity such as cracks, small
spalls or non-honeycombed areas, or any defect that does not
extend beyond the centerline of any reinforcing steel, or to any
elements of the post-tensioning system.
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and Drawings).
Repair of cosmetic defects shall be made in such a manner that the

aesthetics of the segments are restored.
(2) Structural: Structural defects include defects that will impair the
ability of the segment to adequately resist construction or service
loads or reduce the life expectancy of the structure. All defects or
damage that extend beyond the centerline of reinforcing steel or
into elements of the post-tension in system or occur in the deck
portion of the segment are considered structural defects.
Examples of such defects include cracks, largespalls and
honeycombed areas, and major segregation or breakage of
concrete.
The Contractor's Engineer shall be responsible for construction

load analysis, and service load analysis, required to validate the
repair procedure.
Repair of structural defects shall be such that the aesthetics and

structural integrity of the segment are completely restored to a
condition to be expected had the defect or damage not occurred.
(3) Rejectable: Rejectable defects are defects or damage, as

determined by the Engineer in charge, which will impair the ability
of the segment to adequately resist service loads or construction
loads, or will reduce the life expectancy of the structure and that
cannot be successfully repaired such that the structural integrity is
completely restored. Segments with rejectable defects will be
deemed unacceptable and shall be removed from the work and
replaced at no additional cost.
Damaged or defective segments may also be rejected for the
following reasons.
Rejection of proposed repair procedures by the Engineer

Failure of the Contractor to provide the required certification
or demonstration that the repair was successful and that the
defect no longer exists, as required below. Failure of the
Contractor to eliminate recurring defects.
K. Repairs
1. Cosmetic repairs shall only be made following procedures prepared by
the Contractor, and approved by the Engineer in charge.
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and Drawings).
The Contractor's repair procedure shall identify those areas required to be

repaired prior to erection and post-tensioning, and those that must be
repaired after erection and post-tensioning.
2. Structural repairs shall be made following procedures prepared by the

Contractor. The repair procedure shall be signed by the Construction
Engineer, shall be submitted in writing to the Engineer in charge, and shall
include the following minimum information:
a.) A detailed description and sketch of the defect.
b.) The magnitude and type of the most critical construction loading
and service life condition to which the defective area will be
subjected.
c.) Detailed reinforcement requirements, material types, surface
treatments, curing methods, and general repair procedures
proposed. The procedure shall clearly indicate those area required
to be repaired before erection, and those areas to be repaired after
erection.
d.) The specific non destructive testing method and procedure by
which the Contractor shall demonstrate to the Engineer in charge
that the defect no longer exists and the segment has been restored
to a condition to be expected had the defect or damage not
occurred.
L. Shear Key Repairs: Repairs to the shear keys along the webs shall be generally
made after the segments have been erected to prevent
deterioration of the segment matching surfaces. When shear keys
have been damaged, the Contractor shall advise the Engineer
who will make a structural evaluation of the segment, and advise
the Contractor about the acceptability of repairs.
Bidder 111 KDMC

and Drawings).
PART 2 - EXECUTION
3.01 GENERAL
A. The Contractor shall be solely responsible for design, fabrication,
assembly, and operation of all equipment to be used for handling and
erecting segments.
B. Erection of segments shall not begin until the construction documents,
required in chapter 1.04 of these Special Provisions, have been reviewed
and approved by the Engineer in charge.
C. Elevations and alignment of segments shall be carefully measured at each
stage of erection with instruments capable of providing the degree of
accuracy necessary to ensure that erection tolerances will be met.
Deviations from the table of elevations and alignment prepared by the
Contractor shall be corrected so as to prevent accumulation of deviations
using a method submitted by the Contractor and approved by the Engineer
in charge.
3.02 AGE OF PRECAST SEGMENTS AT TIME OF ERECTION:

Precast segments shall not be erected until they have reached the age of 14 days
and have obtained the minimum strength specified in the Design Drawings and as
specified in Section G Test Samples.
3.03 EQUIPMENT
A. General
Design calculations prepared under the direction of a Professional
Engineer shall be prepared for all erection equipment, falsework, and other
temporary construction that may be required to accomplish the work.
B. Load Testing: Prior to using the equipment specifically fabricated for the
purpose of lifting the precast segments, the Contractor shall demonstrate
by a full-scale load test that the equipment is capable of supporting a load
equal to 120 percent of the weight of the segments to be lifted or
supported by the equipment. The full-scale load test shall be conducted
with the equipment subjected to the most extreme loading condition to be
encountered during its use on the Project. Measurements of vertical
deflections and horizontal movements at support points shall be recorded.
The Contractor shall give written notice to the Engineer at least 72 hours in
advance of the time at which load testing of the equipment is to take place.
3.04 ERECTION TOLERANCES:

The following tolerances shall apply to erection of superstructure segments:
A. The maximum differential between the outside face of adjacent segments
in the erected position shall not exceed 5 mm.
Bidder 112 KDMC

and Drawings).
B. Transversely, the angular deviation from the theoretical slope difference

between two successive segment joints shall not exceed 0.001 Rad.
C. Longitudinally, the angular deviation from the theoretical slope change
between two successive segments shall not exceed 0.003 Rad.
D. Dimensions from segment to segment shall be adjusted so as to
compensate for any deviations within a single segment so that the overall
dimensions of the completed structure will conform to the dimensions
shown on the Design Drawings such that the accumulated maximum error
should not exceed 1/1000 of the span length for either vertical profile
and/or horizontal alignment.
3.05 SPECIAL REQUIREMENTS ERECTION OF PRECAST SEGMENTS BY

CANTILEVER METHOD
A. During erection by the cantilever method, the unbalanced loads shall not
exceed that shown in the erection drawing scheme included in the Design
Drawings.
B. Accurate positioning of the segments adjacent to the pier table is critical,
as it will establish the line and grade for cantilevers in each direction. The
alignment and elevations of the cantilevers shall be checked by the
Contractor within 1 hour of sunrise on each day that segments are to be
erected.
C. If measured elevations deviate from the table of theoretical elevations
submitted by the Contractor, a corrective action plan shall be submitted by
the Contractor for approval by the Engineer in charge.
3.06 EPOXY JOINTING OF PRECAST SEGMENTS

A. Epoxy material placement, inspection, and testing shall be in accordance
with AASHTO Materials Specification M235, AASHTO Standard
Specifications for Highway Bridges, Division II, and Construction, Sections
8.13.7 and these Special Provisions.
B. Application and Amount of Epoxy: The application shall begin immediately
after a batch has been mixed. The epoxy bonding agent shall be applied in
accordance with the manufacturer’s recommendations by spatula or
gloved hand to completely and uniformly cover one of the faces to be
joined to a nominal thickness of 2 mm, except that in the vicinity of internal
post-tensioning ducts, it shall be applied to both surfaces to a nominal
thickness of 1 mm. Epoxy shall not be applied to either face within 12 mm
of post-tensioning ducts, conduits or outside edges except that, regardless
of spacing,a bead of epoxy shall be applied between each and all post-
tensioning ductsand conduits.
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and Drawings).
The amount of epoxy may be adjusted providing that a sufficient amount is

applied to completely fill the interstitial space in the joint and to extrude a
small bead from the joint after application of the compressive contact
pressure. If a bead of epoxy is not extruded all around the joint, the joint
may have to be pressure injected with epoxy or other remedial measures
may have to be taken after all internal post-tensioning tendons have been
grouted.
When epoxy is applied in conjunction with layers of woven glass matting

and high-density plastic or other approved material for the purpose of
shimming a joint to correct alignment, then a proposal detailing the areas
and layers of mattin, amounts of epoxy, and operational procedures shall
be submitted to the Engineer in charge for review and approval prior to
implementation.
Application of epoxy bonding agent to the segment joints after combining

the components shall follow the manufacturer’s recommendations.
C. Closing Segment Joints: Immediately after the segment joint is covered

with epoxy bonding agent, the segments shall be brought together and the
specified compressive contact pressure applied in accordance with the
approved erection procedures. A discernible bead line of extruded epoxy
shall be apparent along the exposed edges of the joint or remedial
measures such as epoxy injection may have to be taken as required by the
Engineer.
D. Failure to Comply with Time Limits: The Contractor shall plan his post-
tensioning operations so that the time elapsing between mixing of the
components of the first batch of epoxy bonding agent applied to the
segment joint and application of a compressive force averaging not less
than 0.28 MPa over the entire joint does not exceed the manufacturer’s
recommendations. If this time limit is exceeded, the concrete segments
shall be moved apart and all epoxy bonding agent shall be removed from
both faces of the joint. If solvent is used to remove the epoxy bonding
agent, reapplication of epoxy to the joint surfaces shall not occur until
solvent has dissipated and as approved by the Engineer in charge.
E. Record of Jointing: The Contractor shall keep a record of each joint with
the following details:
1. Segment, span, and joint numbers
2. Date and time of jointing
3. Batch number for resin and hardener
4. Maximum temperature of the mix
5. Weather conditions (temperature and humidity recorded at 15 minutes
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and Drawings).
6. Details of samples
7. Results of tests
3.07 POST-TENSIONING
A. The installation, stressing, grouting, and testing of post-tensioning tendons
shall conform to the requirements of the Special Provisions for Post-
Tensioning.
3.08 CLOSURE JOINTS

A) Concrete for closure joints shall comply with the same specifications and
criteria as the concrete for the precast segments. The concrete shall reach
the minimum required strength as shown in the Design Drawings prior to
stressing the longitudinal post-tensioning tendons. The formwork shall be
adequately supported to take all loads applied and it shall not be removed
until the concrete in the joints has reached a minimum age of twelve hours.
Longitudinal tendons may be stressed when closure concrete has reached
the required design strength or as approved by the Engineer in charge.
B) For mid-span closure joints in cantilever construction, the cantilevers

adjacent to the closure joint shall first be aligned vertically and laterally
following procedures developed by the Construction Engineer. The
cantilevers shall then be restrained by closure beams maintaining the
cantilever's relative positions during construction of the closure joint. The
concrete shall be placed in the closure joint at a time when the
temperature differential between the top and bottom slab is minimum.
3.09 FINAL CLEAN UP

Before final acceptance, the Contractor shall clean the interior of the
concrete box girders of all rubbish, excess materials, loose concrete, dirt,
and debris. The interior of the box girders shall then be swept out. The final
cleanup shall be performed after all work on the interior of the box girders,
including grouting of all tendons and electric work, has been completed.
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and Drawings).
Clause A-12 REINFORCED EARTH RETAINING STRUCTURES

1. SCOPE
This work shall consist of Reinforced Soil Structures providing and

fixing of precast concrete facing units soil reinforcing elements with
accessories / fittings and backfill material and in accordance with the
Specifications and in reasonably close conformity with the lines, grades
design and dimensions shown on the approved drawings.
The design life for the Reinforced Soil Structural shall be hundred (100)
years irrespective of defect liability period specified else where in the
tender document. Additionally, a performance warranty in respect of
this work for 10 years shall have to be submitted. The Contractor(s)
accordingly shall furnish the guarantee bond as directed by the
Engineers – in – Charge.
The work shall generally be done in conformity to the MORT&H
(Ministry of Road Transport and Highways) “Specifications for Road
and Bridge Works” (Fourth Revision August 2001 Reprinted March
2007) Section 3100 and SP-59. The detailed design and drawings of
the work is done I n accordance with the MORT& H Specifications. The
design will also cater for single lane IRC class 70R, two lanes IRC
class A or combination of the two as external live traffic loads for 3 –
lane carriageway full impact loads of vehicle, safety barrier system and
earthquake load as per IS: 193:1984 classification.
2 Reinforcing Element
2.1 General
Since Reinforced Soil is a specified and patented technology, the
Contractor shall furnish design approval by the Engineer in charge and
make his own arrangements to secure the supplies and services
needed.
2.2 Soil Reinforcing Structural Elements
2.2.1 Geosynthetics
The Reinforcing element shall be metallic reinforcing elements, geo-
synthetics, geo-grid reinforcement, geotextile reinforcement and mats
of synthetic grids or any other proprietary material, which may be
approved by the Engineer in charge.
The geo-synthetics material shall be dimensionally stable and able to
retain its geometry under construction stresses and have resistance to
damage during construction, to ultraviolet degradation and all forms (If
chemical and biological degradation encountered) in reinforced earth
structures. These effects must be determined by testing and analysis
as it may cause deterioration of either the geosynthetic / soil stress
transfer mechanisms within the structure.
All quantity control strength of geo-synthetics must represent minimum
average roll values (MAR V) only (95% confidence limit), Testing of
geo-synthetic for tensile strength, ASTMD4595/ISO 10319 shall be
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and Drawings).
performed for every 5000 square meters and test data for each lot of
material shall accompany shipments. Samples of geo-synthetic to be
used for the project shall be submitted along with documentation
notarised by the manufacturer that the material meets the project
Specifications.
Approval of the material by the owner / owner’s engineer will be
required prior to delivery of the material to site.
Since geo-synthetics are manufactured from plastics (polymers), which
are visco-elastic in nature, they are susceptible to creep or long
deformation within the structures in post construction stages. Creep of
polymers is primarily dependent on the soil ambient temperatures. The
manufacturers of geo-synthetics materials must be able to supply
creep test data results for the period of minimum 10000 hours. The
post construction strains in geo-synthetics must be restricted below
0.5% for approach highway retaining walls and for abutments (mixed or
pure type) 10 to meet serviceability state requirements.
The manufacturer / supplier of geo-synthetics material must conduct

site-specific test to assess the potential for construction damage and
strength loss in geo-synthetic based on the quality of backfill soil,
compaction equipment and efforts utilised and type of geo-synthetic
proposed for use. The same shall be accounted in the design as partial
factor of safety for construction. Installation damages, however, if the
supplier is able to provide adequate test data performed by
internationally known and approved test laboratory it shall be accepted.
Specific chemical compatibility tests to account for adverse affects to

pH, chemicals aqueous solutions of salts, acids and alkalis etc. at soil
ambient temperatures of 40ºC (facing temperature) for site specific
backfill soil shall be conducted and accounted in the design as partial
factor of safety from chemical degradation of geo-synthesis.
In Indian conditions geo-synthesis may be subject to strength loss and
damage of its structural integrity from burrowing animals / organisms
like rats, which may use them as food and nutrition value, in spite of
the polymers inertness to support biological activity. Such factors must
be accounted as material factor of safety from biological degradation.
The manufacturers / supplier of the geo-synthetic precast facing
system must conduct tests and the results must sustain the choice of
interaction properties (direct sliding and bonds coefficients) with site
specific backfill materials in design calculations, or provide already
performed test data.
No joining along principal stress direction in geo-synthesis (with
fasteners or connectors) shall be permitted. The width of fabric may be
3 to 5 meters without seams. Joints between widths have to be made
by overlaps.
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and Drawings).
2.2.2 Geogrid Reinforcement

The geogrid shall be made from high molecular weight, high tenacity
polyester (PRT) or High-Density Polyethylene (HDPE).
Polyester geogrids shall be manufactured by the weaving in tension
process to ensure full junction strength and coated with a protective
latex or PVC to maximize the resistance to creep, hydrolysis, pH and
enhance durability during construction and is service. Minimum mass
per unit area (ASTM D 526/ISO 965) of polyester geogrids shall be 250
gsm.
High density polythylene geogrids shall be manufactures by extruded,

drawn sheets and by punched and orientation process in one direction
so that the resulting ribs, which is continued through the integral
transverse bar. It shall contain adequate stabilizers to enhance stability
to environmental stress cracking (ESC), photo oxidation (UV-exposure)
and thermal oxidation. HDPE geogrids must possess 100% junction
efficiency of QC strength (in accordance to GRI-GG2-87 test
requirements) between longitudinal ribs and (ASTM D 5261) of HDPE
geogrids shall be ISO 9001 certified.
2.2.3 Geotextile Reinforcement
Geotextile shall be made from woven high quality polypropylene (PP)

or polyester (PET) fibres. They shall be manufactured from weaving
process. The manufacturer of geotextile by this process will give rise to
warp direction (the cross direction, or short direction) and selvedge
(edges of the fabric where the weft yarns reverse direction and gather
the outer warp yarns on each side of the fabric).
The geotextile must process maximum to creep, hydrolysis

environmental stress checking (ESC) photo oxidation (UV exposure)
thermal oxidation and installation damage as per ASTM.
Geotextile must possess sufficient permeability of prevent build-up of

hydrostatic pressures in the reinforced soil mass. Minimum mass per
unit area (ASTM D 5261) of geotextile shall be 350 gsm.
In all cases, the long term desirable strength (LTDS) shall be

calculated by using the following minimum values of material partial
factor of safety based on 100 years service design life in absence of
BS – 8006 : 1995 prescribed values.
Bidder 118 KDMC

and Drawings).
Minimum Partial FOS HDPE PET Woven Woven

for calculation of 100 based geogrids PP based PET
years long term design geogrids geotextile based
strength (TD) in s geotextile
accordance with BS – s
8006: 1995
requirements
Partial FOS for
deformation (at 40C to
meet less than 0.5% post
5.5 2.75 6.0 3.0
construction strain
requirement for retaining
wall cases)
Partial FOS for variations
1.0 (use 1.0 (use 1.0 (use 1.0 (use
in manufacture from
only only only only
control specimens (fm
MARV) MARV) MARV) MARV)
12)
Partial FOS for 1.10 1.10 1.10 1.10
extrapolation of creep (10000 (10000 (10000 (10000
test data (fm 21) hours hours hours hours
creep) creep) creep) creep)
Partial FOS for
construction / installation
1.18 1.22 1.83 2.44
damage (susceptibility to
damage) (fm 22)
Partial FOS for potential
chemical (at 40C) and
1.10 1.15 1.10 1.15
biological degradation
(Environment) (fm 22)
FOS – Factor of Safety
Value of the strain at nominal strength
Longitudinal maximum 12.5%

Transverse maximum 12.5%
Total warp strain including creep at 10000 hours loading shall not
exceed 8% at 50% of ultimate tensile strength. The total post
construction strain for the design life of structure at allowable design
load shall not exceed 1% (in accordance with BS:8006). Tensile
strength and strain of geogrid shall be tested in accordance with EN
ISO 10319. Mechanical properties shall be verified for both internal and
external control and assurance by an independent and accredited
laboratory.
2.2.4 Precast Concrete Facing
The precast concrete facing units will be discrete panels or modular

concrete block units having maximum longitudinal transversal and
Bidder 119 KDMC

and Drawings).
rotational flexibility to cater high static and dynamic loads, and ground
movements.
2.2.4.1 Concrete Panel Facing
Precast concrete facing elements shall conform to the details and

dimensions shown on the drawing. Concrete shall be grade shown on
the drawings and shall conform to the requirements specified in section
1700 “Structural Concrete”.
The nominal thickness of the panel shall be 18 cms including facing

textures and design. The grade of concrete shall be minimum M-40.
Reinforcement in panels shall be designed for the connections with soil

reinforcing structural elements and shall be placed as shown on the
plan and shall conform to the requirements specified in IRC 21-1987.
Casting
The elements shall be cast on a flat area. Tie strips connecting pins,
PVC pipes and lifting anchors shall be set in place to the dimensions
and tolerances shown on the drawing and tie strips guides shall be set
on the rear face, prior to casting. The concrete in each unit shall be
placed without interruption and shall be compacted by the use of an
approved vibrator supplemented by such hard tamping as may be
necessary to ensure that the concrete reaches into the corners of the
forms and prevent formation of stone pockets or cleavage plans. Clear
form oil of the same manufacturer shall be used throughout the casting
operations.
Curing
The elements shall be cured for a sufficient length of time as approved

by Engineer so that the concrete develops the required compressive
strength. Only fresh potable water shall be used for curing.
Removal of Forms
The forms shall remain in place until they can be removed without
damaging the elements. The scheme of removal of formwork shall be
as per relevant Specifications.
Scribing
The data of manufacture and batch number shall be clearly scribed on

tile rear face of each unit.
Bidder 120 KDMC

and Drawings).
Concrete Finish
The front (exposed) face of the elements shall have the finish approved
by the Engineer in charge and painted with cement based waterproof
paint. The rear face shall have the finish of unformed surface and shall
be roughly screened to eliminate open pockets of aggregates.
Tolerances
All elements shall be manufactured within the following tolerances:
All dimensions within 5 mm
Evenness of the front face ±5 mm over

1500 mm
Difference between lengths of two 10 mm max

diagonals
Thickness ±5 mm
Handling, Storage and Transporting
All elements shall be handled, stored and transported in such manner

as to eliminate the danger of chipping, cracks, fracture and excessive
bending stresses. Elements in storage shall be supported of firm
blocking located adjacently the lie-strips to avoid bending.
Acceptability
Acceptability of the precast elements shall be determined on the basis

of compression tests, as per MORT & H Specifications and visual
inspection. A minimum of one sample of 6 cubes shall be cured in the
same manner as the elements and tested to determine when the
elements can be placed in the structure. Elements shall be acceptable
for placements in the structure of the strength all 7 days, or before,
exceeds 75% of the 28 days requirements.
Rejection
Elements shall subject to rejection in case of failure to meet any of the

requirements specified above. In addition, defects, which indicate
Imperfect moulding, or defects indicating honeycombed or open
textured concrete shall be sufficient cause for rejection.
2.2.4.2 Levelling Concrete
A levelling concrete pad shall be provided under walls and seat beams
(for bridge abutments). Concrete shall have a minimum grade M-15
(150 kg / sqm.) Maximum size of aggregates shall be 20mm the pad
shall cure for 24 hours at least to placing panels.
Bidder 121 KDMC

and Drawings).
2.2.4.3 Joint Fillers
Fillers of vertical joints between panels shall be flexible open cell

polyurethane foam strips or non-woven fabric strips (the latter used as
joint cover installed of filter) as approved by Engineer in charge.
Bearing pads for horizontal joints between panels shall be made of
elastomer with vulcanized EPDM.
2.2.4.4 Drainage
Drainage shall be very strictly followed as per drawing and

Specifications in detail. The Reinforced Earth backfill is considered a
self-drainage media, having sufficient permeability to relieve
hydrostatic pressures. However, water logging in the reinforced fill
increases the pore pressure co-efficient thereby resulting in tensile
forces in Reinforced Soil Structure, reducing the stability of structure.
Wherever, there is a probability of such occurrence, drainage outlets at

the bottom level joints of panels with provision of non-woven geotextile
backing shall be provided along the facia for drainage redundancy. The
retained fill shall have drainage bay 19.5 mm to 9.1 mm well graded
crushed aggregate to allow free drainage of the reinforced fill along
with the retained fill. The panel joints above 300mm of existing ground
level shall be filled with joint fillers 6.
2.2.4.5 Modular Concrete Facing Block Units
The facing element of geosynthetic retaining wall will consist of

segmental / modular concrete block units, as alternate discrete panel
facing.
These units will be dry stacked (without mortar) one over the other in a
running bond configuration, vertically adjacent units shall be connected
by dowels or shear pins to ensure positive connection with the
reinforcing geosynthetic. Tongue and groove type connections are also
acceptable provided they ensure restriction of movements to 12.5mm
(serviceability movements) at 1.5 times the geo-synthetic long term
allowable design strength at a post construction creep strain of less
than 0.5~1 for approach and highway retaining walls and abutment
walls (applicable to both bank seat load carrying pure, abutments or
mixed type abutments) based on AASHTO requirements.
The minimum weight of each such unit will be 30 Kgs. The minimum
grade of concrete shall be M-40 as per IRC guidelines. The minimum
depth (perpendicular to wall) of these units will be 250 mm. Only
vertical wall shall be constructed with the final facing batter not
exceeding 1 in 10.
Bidder 122 KDMC

and Drawings).
The spacing between primary reinforcing geo-synthetic shall not be

more than 600mm.
Casting
Modular concrete facing W lits will be manufactured by dry casting
process by fully automatic block making to ensure consistent quality of
concrete, dimensional tolerance, good finish and aesthetic
appearance.
Curing
The precast blocks shall be cured for a sufficient length of time as

approved by Engineer in charge so that the concrete develops the
required compressive strength. Only fresh potable water shall be used
for curing. Steam curing is desirable.
Concrete Finish
All units shall be sound and free of cracks or other defects that would
interfere with the proper placing of units or significantly impair the
strength or permanence of the construction. Any block units with
cracks or chips observed during construction shall be rejected from
use.
Tolerances
Modular concerte block units dimensions shall not differ more the ± 3.5
mm except height, which shall differ more than ± 1.5 mm.
Modular concrete block units match the colour surface finish and
dimension for height, width, depth and batter but not exceeding 1 in 10
to vertical.
Handling Storage and Transporting
All elements shall be handled, stored and transported in such manner

as to eliminate the danger of chipping, cracks, fracture and excessive
breaking stresses. Elements in storage shall be supported on firm
blocking.
Acceptability
Acceptability of the precast elements shall be determined on the basis

of compression tests, as pre MORT&H Specifications and visual
inspection. A minimum of one sample of 6 cubes shall be taken for
each lot of 5 cubic meter or part thereof produced per day. 50% of
these cubes shall be cured in the same manner as the elements and
tested to determine when the elements can be placed in the structure.
Elements shall be acceptable for placement in the structure if the
strength at 7 days, or before, exceeds 75% of the 28 days
requirements.
Bidder 123 KDMC

and Drawings).
Levelling Concrete
A leveling concrete pad shall be provided under walls and seat beams
(for bridge abutments). Concrete shall have a minimum grade M-15
(150 kg/cm2). Maximum size of aggregates shall be 20mm. the pad
shall be cured for 24 hours at least to placing panels / modular blocks.
2.2.4.6 Fasteners
Dowels or pins used by the retaining wall supplier to interconnect block

units, shall consist of non degrading polymer or galvanized steel and
be made for the use with the block unit manufacturer.
2.2.4.7 Drainage
a) Drainage Aggregate
Drainage aggregate bay behind the block wall facing (minimum 450mm
thick) shall be clean crushed stone or granular fill meeting the
gradation requirements of backfill soil.
b) Drainage Pipe
The drainage collection pipe shall be a performed or slotted, PVC or

corrugated HDPE pipe. The pipe and drainage aggregate may be
wrapped with a geotextile that will function as a filter. Outlets shall be
provided at suitable locations.
c) Geotextile Filter
Drainage geotextile shall meet the filter criteria based on backfill soil
properties.
2.2.5 Reinforced Earth Backfill
Backfill materials used in the reinforced Soil volume shall be

reasonable free from organic or otherwise deleterious materials and
shall conform to the following mechanical and physico- chemicals
requirements.
Mechanical requirements
Sieve Size Percent Passing

250 mm 100%
100 mm more than 75%
200mm less than 15%
Bidder 124 KDMC

and Drawings).
Coefficient of uniformity Cu = (D60/D10) 2

Acceptance limits for materials with more than 15% passing the # 200
sieve are related to the percentage of particles smaller than 15 microns
as follows:
 Material with more than 15% passing # 200 but less than 100% of
particles smaller than 75 microns are acceptable.
 Material with more than 15% passing # 200 and more than 20% of
particles smaller than 75 microns are inadequate and shall not be used
except as specified in (e) below.
 Materials with more than 15% passing #200 and 10 to 20% of particles
smaller than 75 microns are acceptable provided that the internal
friction angle is nor smaller than 25.
Physico-chemical requirements:
Materials with a receptivity of 5000  cm or more are readily
acceptable, based on a standard test as directed by the engineer in
charge.
Materials with resistivity less than 1000  cm are inadequate and shall
not be used except as specified in (e) below.
Materials with resistivity between 5000 and 1000  cm are acceptable
provided that in water extracted from soil water mix, the content of
chlorides does not exceed 200 ppm, the content of sulphates does not
exceed 1000 ppm, and the pH value is in the range of 4 to 9.
The foundation soil physico – chemical requirements should also meet
the above criteria. If not special consideration will be given to the
design of reinforcing geo-synthetic and fitting blocks.
Quality Control
For every 300 cum of backfill material, or whenever the approved

source is changed, one sieve analysis and one measurement of
resistivity and angle of internal friction shall be carried out. The results
will indicate what further tests are needed, if any.
Water for Compaction

Water of minimum resistivity exceeding 700  cm shall be used for
compaction.
Materials not conforming to the above requirements may be used with
the written consent of Engineer after carrying out test. Such materials
shall be tested for their functional properties to assure that they are
consistent with the parameters used in the design calculations.
Compaction
The compaction layer should not be more than 250 mm.
The compaction of backfill material shall be 97 percent of maximum
laboratory density measured as per IS:2720 (Part 8) for one – meter
Bidder 125 KDMC

and Drawings).
depth below road crust and 95 percent of maximum laboratory density

measured as per IS : 2720 (Part 8) for remaining portion of fill
materials.
2.3 Construction Requirements

2.3.2 Reinforcing Geo-Synthetic with Modular Concrete Block Units
2.3.2.1 Excavation
The Contractor shall excavate to the lines and grades shown on the
project grading plans. The Contractor shall take precautious to
minimize over excavation. Excavation support, if required shall be
designed by the Contractor.
2.3.2.2 Foundation Preparation
The foundation for reinforced Soil Structures shall be graded level for a
width equal to or exceeding the length of reinforcing geo-synthetic.
Prior to wall construction, if required by the engineer in charge, the
foundation shall be compacted with a smooth wheel vibratory roller.
Any foundation soil found to be unsuitable shall be removed and
replaced.
2.3.2.3 Levelling Pad Preparation
The leveling pad shall consist of 200 mm thick and 800 mm wide
concrete strip footing in M-15 grade. Alternatively, a minimum 200 mm
thick layer of compacted granular material shall be placed for use as a
leveling pad upto the grades and locations as shown on the
construction drawings. The granular base shall be compacted to
provide a firm level bearing pad on which to place the first course of
concrete modular retaining wall units. Compaction should be
performed to obtain a minimum of 95% of the maximum standard
Proctor Density (ASTM D 698).
2.3.2.4 Modular Concrete Block Units and Geo-Synthetic Reinforcement

Replacement
a) All materials shall be installed at the proper elevation and orientation
as shown in the wall details on the construction plans or as directed by
the Owner’s Engineer. The drawings shall govern in a conflict between
the two requirements.
b) Overlap of the Geosynthetic in the design strength shall not be
permitted. The design strength direction in the length of geo synthetic
reinforcement perpendicular to the wall face and shall consist of one
continuous piece of material. Adjacent sections of geo synthetic shall
be placed in a manner to assure that the horizontal coverage shown on
the plans is provided. A minimum 100 mm overlap shall be allowed
between adjacent roll widths.
Bidder 126 KDMC

and Drawings).
c) Geo synthetic reinforcement should be installed under tension. A

nominal tension shall be applied to the reinforcement and maintained
by staples, stakes or hand tensioning until the reinforcements has been
covered by at least 200mm of soil fill.
d) Broken, chipped, stained or otherwise damaged units shall not be
placed in die wall unless they are repaired and the repair method and
results are approved by the Engineer in charge.
2.3.2.5 Backfill Placement

The reinforcing elements shall be laid free from all kinks, damage and
displacement during deposition spreading, leveling and compaction of
the fill. The programme of filling shall be such that no construction plant
runs directly on the reinforcement.
All construction plant having a mass exceeding 1000 kg shall be kept
at least 1.5m away from the face of slope or wall. In this area (upto 1.5
m from the face of slope or wall) following compaction plant shall be
used.
(i) Vibratory roller having a weight per meter width of roll not exceeding
1300 kg with total weight not exceeding 10,000 kg.
(ii) Vibratory plate compactor of maximum weight 1000 kg.
(iii) Vibro tamper having a weight 1000 kg.
Compaction by any other method like using dozer or back blade
compaction by dozer or excavator bucket shall be permitted with due
approval from the engineer after ascertaining the level of compaction
so achieved.
During construction of reinforced fill, the retained material beyond the
reinforcement at the rear of the structure shall be maintained at the
same level as reinforced fill.
Temporary formwork shall be used to support the construction as per
specified details given in the drawing. The forms, scaffolding and
props shall be sufficient in numbers to allow taking up of a sectoral
construction schedule specified in the design.
2.3.2.6 Drainage Fill placement
a) Drainage fill shall be placed to the minimum finished thickness and

widths shown in the construction plans or as modified by the Owner’s
Engineers.
b) Drainage collection pipes shall be installed to maintain gravity flow of

water outside of the reinforced soil zone. The drainage collection pipe
should be laid into a stone sewer manhole or along a slope at an
elevation lower than the lowest point of the die pipe wide in the
aggregate drain.
Bidder 127 KDMC

and Drawings).
c) The main collection drain pipe just behind the block facing shall be a
minimum of 150mm in diameter. The secondary collection drain pipes
should be sloped minimum of two percent to provide gravity flow into
the main drainpipe. Drainages laterals shall be spaced at maximum 15
metres spacing along the wall face.
2.3.2.7 Cap Block Placement

The cap block and/or top modular concrete block unit shall be bonded
to the modular concrete block units below using cap adhesive.
2.4 Designs, Working, Drawing, Detailing and Supervision

The scope of work will also cover the supply of detailed design,
engineering submission, working drawings by the specialized agency
for reinforced soil works. The designs and drawings shall be got
approved from the Engineer in charge and / or its representative before
execution of work. A technical representative of the supplier/
manufacture shall be present on site throughout during the casting and
erection phases to ensure that the quality of the works performed by
the Contractor is in accordance to the Specifications.
All expenses relative to his presence on site shall be borne by the
agency.
2.5 Inspection
Engineer and/or the representative is responsible for verifying the
materials supplied by the Contractor, meets all the requirements of the
specifications. This includes all submittals and proper installation of
the system.
As requested by the Engineer and/or its representative the reinforced

earth retaining wall system supplier shall provide a qualified and
experienced representative on site to assist the contractor regarding
proper wall installation.
The contractor’s field construction supervisor shall have demonstrated

experience and be qualified to direct all work at the site.
Measurements for Payment

This clause is modified as under:
Measurement for facia shall be in sq. metres above the foundation
beams. This shall include cost of foundation beam facia panels, all
reinforcing elements for which no separate measurements shall be
taken, all accessories and foundation treatment, if required.
Measurement for compacted earth fill shall be in cubic metres for
compacted soil.
Measurement for crash barrier including friction slab and steel pipes
with fixing plates shall be in linear m.
Bidder 128 KDMC

and Drawings).
Rates
This clause is modified as under:
Para 1 is modified as under:
Rates shall include cost of design, providing labour, material, plant
hire, material storage and handling expenses erection, supervision
etc. for completing the works.
Para 2 is deleted
Para 3 is modified as under:
Rate for facia panels shall include cost of facia panels joints, all
necessary temporary formwork, scaffolding and all lifts and leads as
shown in the drawing. It shall also include cost of providing
reinforcing elements including cost of material, all transportation cost
and storage of the same as per special provisions. This shall also
include cost of laying of the reinforcing elements including all
overlaps, jointing and stitching, heat bonding or extension, etc. This
shall also include cost of foundation beam including all items of
excavation, concrete, reinforcing steel, formwork, labour and
equipment. The rate includes detailed design of the structure.
Para 4 Rate for soil fill shall include providing fill material as per
clause 3103, compaction as desired in requisite layers through
mechanical means, cost of hire or labour for plant operations,
dressing and levelling slopes, including special measures for edge
reinforcements as shown in the drawing.
Add para 5 as under:
The rate for crash barrier shall include the cost of crash barrier
including friction slab, reinforcement, steel pipes, fixing steel plates
complete including painting of steel work with one coat of Primer and
2 coats of approved paint.
Bidder 129 KDMC

and Drawings).
CLAUSE SP -13 STRUCTURAL STEEL WORKS
1. General
Fabrication and Erection of Steelwork shall be done according to Indian Railway
Standard – “Specification for Fabrication and erection of Steel girder Bridges and
Locomotive Turn-Tables” – Serial No B1-2001.
The above specifications shall be read in conjunction with the Indian Railways
codes /standards, Metro Railway specifications, specifications given hereafter,
CPWD specifications 1996 and other relevant reference specifications described
in thebsection 1 of these specifications. However, in case of any contradiction,
Railway Standard B1 shall prevail.
Definitions:
Definitions of the various terms used in the specification for steel work shall be the
same as given in the Railway Standard B1-2001-“Specification for Fabrication and
erection of Steel girder Bridges and Locomotive Turn-Tables”
Contractor’s responsibilities
The Contractor will provide all materials and equipment required to complete the
works in every respect, whether such materials are required as part of the
permanent structures or temporary for fabrication or erection or maintenance
including specifically structural steel plates, shapes, flats, bars, welding rods,
rivets, bolts andnuts, paint, welding sets in the shop and at site, all workshop
facilities, derricks,cranes, pulley blocks, wire ropes, slings, hemp or manila ropes,
winches, small tool sand tackles, jacks, erection cleats and temporary braces or
supports and all other materials required to deliver the Works complete in every
respect.
All labour required for fabrication and erection for any cleaning, making good,
rectifying, hauling, and painting and for any other ancillary work required to
complete fabrication and erection.
The Contractor shall observe all safety requirements for erection of structural steel
work as covered in IS: 7205.
2. Drawings
(i) The Engineer will supply to the Contractor profile drawings showing sizes
of all structural members and typical connection details.
(ii) Should there be any discrepancy in the drawings the Contractor is to refer
the matter to the Engineer. The Contractor shall further provide a drawing
showing the accurate setting out to line and level of all the anchor bolts
intended for the work in sufficient time for their inclusion in the work so as
to maintain the building program.
Bidder 130 KDMC

and Drawings).
(iii) The Contractor is to prepare all the necessary fabrication shop drawings
and these shall be submitted to the Engineer in charge in duplicate and be
approved by him before fabrication is commenced. All such drawings shall
show the dimensions of all parts, method of construction, welding and
bolting. A further set of all approved fabrication drawings shall be supplied
by the Contractor for use of the Engineer in charge as required.
(iv) Approval by the Engineer in charge of drawings or any other particulars
submitted by the Contractor shall not relieve the Contractor of full
responsibility for any discrepancies, errors or omissions therein. The
Contractor shall at his own expense supply such additional copies of his
working drawings as are required for the use of the interested parties.
3. Material
(i) Structural Steel
All structural steel shall be of tested quality and shall conform to one of the
following standards:
a) IS 2062 E 410 class killed and normalized / control-cooled.
b) IS 2062 E 550 class killed and normalized / control-cooled and copper

bearing for high tensile steel; in addition material shall comply with
IRS: M42 Grade 1 for riveted / bolted work and Grade II for welded
work. Note: Plates less than 12 mm thick need not be normalized
or control-cooled
c) Steel for bolts shall comply with property class 6.6 as specified in IS
1367
d) Steel for drifts shall be accordance with IS:1875 for forged quality steel
or IS:7283 for hot rolled bars
e) Steel for rivet bars shall comply with the requirements of IS:1148 for
hot rolled rivet bars and IS:1149 for high tensile rivet bars for general
structural purposes. For high strength low alloy structural steel rivet
barsw t enhanced corrosion resistance for use in bridges, steel shall
comply with the requirement of IRS:M-43
f) The dimensions of all rolled sections must agree with the contract
drawings or as agreed to between the Purchaser and the Contractor.
g) The rolling and cutting tolerances shall be in accordance with 15:1852 or

as agreed to between the Purchaser and the Contractor if closer
tolerances are desired they shall be shown in the drawing.
Bidder 131 KDMC

and Drawings).
h) All the steel sections used in thenfabrication must have mill test
certificatednearly indicating the specification to which the steel
conforms and whether steel is killed and normalized. All tile cast mark
numbers/ heat marknnumbers, shall be recorded along with the
number of plates in a register as soon as the plates are received in the
workshop. Whenever the steel isnreceived without any test certificate,
a sample test piece from plate of each cast mark number is to be cut
and sent for testing. Only when it isnestablished that the plates are of
required specification these shall benprocessed for cutting.
i) Use of steel of any quality other than those mentioned above would
require the prior approval of the Engineer in charge.
Pins and Expansion Rollers
j) Pins arid Expansion Rollers shall be made from steel conforming to

15:2004(Class 3 steel).
k) Expansion rollers may, alternatively be turned from approved carriage

and wagon axles only, axles manufactured after 1931 shall be used for
the manufacture of rollers. USFD test shall be conducted to ensure
freeness from internal flaw. Test pieces shall be left as an integral part
of the roller with the stamp of the supplier on it so that the Accepting
Authority can cut off the test pieces and check if required.
The following codes shall also be applicable
IS: 34:- Basic carbonate of lead for paints.
IS: 51:- Zinc chrome for paints.
I S: 57:- Red lead for paints and other purposes.
IS: 75:- Linseed oil, raw and refined.
IS: 77:- Linseed oil, boiled for paints.
IS:102 :- Ready mixed paint, brushing, red lead, non setting, priming.
IS: 104:- Ready mixed paint, brushing, zinc chrome priming.
IS: 123 Ready mixed paint, brushing, finishing, semi gloss, for general
Purposes to Indian Standard colours. IS: 209 Zinc ingot IS: 210
Grey iron casting IS: 549 Split pins IS: 808 Dimensions for hot
rolled steel beam. Column, channel and angle sections.
IS:813:- Scheme of symbols for welding
IS: 814:- Covered electrodes, for, manual metal arc welding of carbon and
carbon manganese steel.
IS: 816:- Code of practice for use of metal arc welding for general
construction in mild steel.
IS: 817:- Code of practice for training and testing of metal arc welders
Bidder 132 KDMC

and Drawings).
IS: 818:- Code of Practice for safety and health requirements in electric and
gas welding and cutting operations
IS: 822:- Code of procedure for inspection of welds.
IS: 823:- Code of procedure for manual metal arc welding of mild steel
IS: 887:- Animal tallow.
IS: 958:- Temporary corrosion preventive grease, soft, film cold, application.
IS: 962:- Code of practice for architectural and building drawings.
IS: 1030:- Carbon steel castings for general, engineering purposes.
IS: 1148:- Hot rolled steel rivet bars (upto 40mm dia) for structural purposes.
IS: 1149 High tensile steel rivet bars for structural purpose. IS:
1363 Hexagon head bolts, screws and nuts of product grade C. IS:
1364Hexagon head bolts, screws arid nuts of product grade A and
B. (allparts)
IS: 1367:- Technical supply conditions for threaded fasteners all parts
IS: 1387:- General requirements for the supply of metallurgical materials
IS: 1458:- Railway bronze ingots and castings.
IS: 1599 :- Method for bent test
IS: 1673 Mild steel wire cold heading quality.
IS: 1730 Steel plates, sheets, strips and flats for structural and general
engineering purposes-dimensions.
IS: 1745 Petroleum hydrocarbon solvents.
IS: 1852 Rolling and cutting tolerances for hot rolled steel products
IS: 1875 Carbon steel billets, blooms, slabs and bars for forging.
IS: 1929 Hot forged Steel rivets for hot closing (12 to 36 mm diameter)
IS: 2002 Steel plates for pressure vessels for intermediate and
hightemperature service including boilers.
IS: 2004 Carbon steel forging for general engineering purposes.
IS: 2016 Plain washers
IS: 2062 2011-Hot Rolled Medium and High Tensile Structural Steel
specification. IS: 2074 Ready mixed paint, air drying, red oxide zinc
chrome, priming IS: 2339 Aluminium paint for general purposes, in
dual container IS: 2590 Primary aluminium ingots for re melting for
general engineering purposes.
IS: 2638 Flat split cotters.
IS: 3063 Fastners single coil rectangular section spring washers.
IS: 3502 Steel chequered plates.
IS: 3613 Acceptance test for wire flux combination for submerged arc
welding
IS: 3640 Hexagon fit bolts
IS: 3658 Code of practice for liquid penetrant flaw detection
Bidder 133 KDMC

and Drawings).
IS: 3664 Code of practice for ultrasonic pulse echo testing by contact and
immersion methods
IS: 3696 Safety codes for scaffolds and ladders
IS: 3757 High strength structural bolts
IS: 4353 Submerged arc welding of mild steel and low alloy steels –
recommendations
IS: 4899 Ferritic and martensitic steel casting for use at low temperatures
IS: 5369 General requirements for plain washers and lock washers.
IS: 5334 Code of practice for magnetic particle flaw detection of welds
IS: 5372 Taper washers for channels.
IS: 5374 Taper washers for I beams.
IS: 5666 Etch primer.
IS: 5905 Sprayed aluminium and zinc coatings on iron and steel.
IS: 6586 Recommended practice for metal spraying for protection of iron
steel.
IS: 6610 Heavy washers for steel structures. IS: 7215 Tolerances for
fabrication of steel structures
IS: 7283 Hot rolled bars for production of bright bars and machined partsfor
engineering applications.
IS: 8629 Code of Practice for Protection of Iron and Steel structures
fromatmospheric corrosion
IS: 9954 Pictorial surface preparation standards for painting of steel surfaces
IS: 9595 Metal arc welding of carbon and carbon manganese steels
recommendations.
IS: 2843 Tolerances for erection of steel structures
IRS Specifications
R 19 Wheels and axles for carriages and waqons.

M3 Class I, II, III & IV steel forgings, blooms for forgings and Billets for
rerolling.
M 28 Classification, testing and approval of metal arc welding electrodes for use
on Indian Railways.
M 39 Classification, testing approval of sub merged arc welding wire flux
combination.
M 41 Corrosion resistance steel.

M 42 High strength low alloy structural steel with enhanced corrosion resistance
Bidder 134 KDMC

and Drawings).
M 43 High strength low alloy structural steel rivet bars with enhancedcorrosion
resistance.
T 12 Flat bottom railway rails.
P 31 Zinc chromate read oxide primer.
ROSO's Specifications
M&C/PCN/102196 Epoxy zinc phosphate primer.

M&C/PCN/103l86 Epoxy micaceous iron oxide
M&C/PCN/109/88 Polyurethane red oxide.
M&CIPCN/110/88 Polyurethane aluminium.
M&C/PCN/111188 High build Epoxy paint.
The Contractor shall supply to the Engineer in charge copies of the manufacturer
certificate that the steel brought to the site for incorporation in the works is of a
quality fully complying with the specification. If required by the Engineer in charge,
the Contractor shall arrange for testing of the steel samples as per IS: 1608 -1599.
ii) Welding Electrodes
Welding electrodes used for the works shall conform to IS:814/latest and shall be
supplied by manufacturer approved by the Engineer in charge and shall be of the
grade approved by the Engineer in charge. All Electrodes shall be kept under dry
conditions. Any electrode which has part of its flux coating broken away or is
damaged shall be rejected.
(iii) Bolts and Nuts
Bolts and nuts used for the works shall unless otherwise specified be black bolts
and nuts supplied by manufacturer approved by the Engineer in charge and shall
conform to IS: 1367.
(iv) Washers
Plain washers shall be made of mild steel conforming to IS: 5369 (1975), unless
otherwise specified. One washer shall be supplied with each bolt and, in case of
special types of bolts; more than one washer as needed for the purpose shall be
supplied. An additional double coil helical spring washer, conforming to IS : 6755
(1980), shall be provided for bolts carrying dynamic or fluctuating loads and those
in direct tension.Tapered washers, conforming to IS: 5372 (1975) and IS: 5374
(1975), shall be used for channels and beams respectively wherever required.
For all other material required for the works, the approval of the Engineer in
charge shall be obtained by the Contractor prior to the use of the material in the
works
Bidder 135 KDMC

and Drawings).
4. Workmanship and Fabrication:

4.1 The whole work shall be representative of the highest class of workmanship. The
greatest accuracy shall be observed in the design, manufacture and erection of
every part of the work to ensure that all parts will fit accurately together on
erection. For manufacture of the components of all spans to be made strictly
interchangeable as specified in clause 33, approved set of same jigs and
assembly fixtures shall be used. The-tolerances in manufacture shall be in
accordance with as shown in Appendix II. The Contractor shall state which of the
following alternative methods of manufacturehe/ she intends to adopt
i) The whole of work to be erected complete and pieces marked to place.
ii) All spans to be made strictly interchangeable as specified hereafter
The Contractor shall maintain a master steel tape of approved make for
which he/ she has obtained a certificate of accuracy from any National
Test House or Government recognized institutions competent to do so.
4.2 Templates
The templates through out the work shall be of steel. The template shall be used
for marking of cutting material and as well as profile machining for girders of
railway loading. Templates shall be used for marking of drilling holes in steel
structures other than girder of railway loadings. In case where actual materials
from a bridge have been used as templates for drilling similar pieces the Engineer
in charge / his representative will decide whether they are fit to be used as part of
the finished structure.
4.3 Flattening and Straightening

All steel materials, plates, bars and structurals shall have straight edges flat
surfaces and be free from twist. If necessary, they shall be cold straightened or
flattened by pressure before being worked or assembled unless they are required
to be of curvilinear form. Pressure applied for straightening or flattening shall be
such as it would not injure the material and adjacent surfaces or edges shall be in
close contactor at uniform distance throughout.
Flattening and straightening under hot condition shall not be carried out unless
authorized and approved by the Engineer in charge / his representative.
4.4 Planning and Shearing

Except where otherwise indicated, cutting of all plates and sections shall be
affected by shearing or sawing, all edges shall be clean, square and true.
Wherever possible the edges shall be cut in a shearing machine, which will take
the whole length of the plate in one cut.
Should the inspection find it necessary, the cut edges shall be ground afterwards.
Bidder 136 KDMC

and Drawings).
Planning or machining of the edges or surface shall be carried out when so

specified in the contract drawings or where specifically ordered by the Engineer in
charge. Where machining is specified, the plates or all sections shall be cut in the
first instance to such a size so as to permit not less than 3 mm of metal being
removed from each sheared edge or end, in the case of plates or sections of
12mm or less in thickness and not less than 6mm or metal being removed in the
case of plates and sections exceeding 12 mm in thickness.
The butting ends of all booms and struts where spliced shall be faced in an end
milling machine after members have been left completely fabricated. In the case
of compression members, the face shall be machined so that the faces are at right
angle to the axis of the members and the joint when made, will be in close contact
throughout. At the discretion of the Engineer in charge / his representative, a
tolerance of O.4 mm may be permitted at isolated places on the butting line.
4.5 Flame Cutting

Flame cutting by mechanically controlled torch/torches shall be accepted both in
the case of mild steel and high tensile steelwork. Provided the edge as given by
the torch is reasonably clean and straight, plates may be cut to shape and beams
and other sections cut to length with a gas cutting torch, preferably oxyacetylene
gas should be used.
4.6 All flame cut edges shall be ground to obtain reasonably clean square and true
edges. Drag lines produced by flame cut should be removed. Unless machining
has been specifically provided for, special care is to be taken to ensure that ends
of all plates and members are reasonably in close contact and the faces are at
right angles to the axis of the members and joints, when made, are also
reasonably in close contact
Use of multi-head flame cutting machine having multiple oxy acetylene torches is
desirable for higher productivity and reducing the distortion due to cutting
operation. Plasma arc cutting method can also be employed. This process offers
less heat input causing less distortion:
4.6 Drilling
All, holes shall be drilled. Holes for countersunk heads of rivets, bolts or screws
shall be drilled to the correct profile, so as to keep the heads flush with the surface
Holes for countersunk heads of rivets, bolts or screws shall be drilled to the
correct profile so as to keep the heads flush with the surface.
Holes for turned bolts should be 1 mm under drilled in shop and should be reamed
at site to suit the diameter of turned bolt.
Bidder 137 KDMC

and Drawings).
Where the number of thicknesses to be rivetted exceeds three or the total

thickness is 90 mm or more, the rivet holes, unless they have been drilled through
steel bushed jigs, shall be drilled out in place 3 mm all round, after assembling. In
such cases the work shall be thoroughly bolted together
The steel bushes shall be case hardened by an approved process and checked
for diameter after the heat treatment. The bores of bushes shall initially have a
tolerance of –0.1mm, 0.1 mm. The tolerance shall be checked from time to time
and when the bores exceed a tolerance of –0mm, +0.4mm, the bushes shall be
rejected. For this purpose, go and no-go gauges are to be used. Tolerances for
checking jigs from master plates shall be +0mm-0.13mm.
The work shall be taken apart after drilling and all burrs left by the drill and the
'sharp edges of all the rivet holes completely removed
4.7 Parts in Contact

All steel work intended to be rivetted or bolted together shall be in contact over the
whole surface.
Drifts as shown in Fig. 2 may be used for drawing light members into position but
their use on heavy members should be restricted to securing them in their correct
positions. In no case, shall drifting be allowed to such an extent that holes are
distorted.
Drifting to enlarge unfaired holes is prohibited. The holes that will have to be
enlarged to admit rivets should be reamed provided the Engineer in charge
permits such reaming after satisfying himself about the extent of inaccuracy' and
the effect of reaming on the soundness of the structure. The Employer / Engineer
in charge retain the right to reject all steel work if the holes are not properly
matched.
4.8 Making of Joints
Cleaning of permanent contact surfaces: – Surfaces which will have permanent

contact, shall be removed of paints and mill scale down to bare metal, clean and
dried and immediately a coating of red lead to IS:102 shall be applied. Care shall
be taken to see that all burrs are removed and no surface defects exist before the
Parts are assembled.
Bolting and Drifting-Only barrel drifts as per Fig. 2 (please refer sketch at the end
of this section) shall be used in erection. They may be used for drawing light
membersinto position; but their use on heavy members shall be restricted to
securing them int heir correct position. Any apparent error in shop work, which
Bidder 138 KDMC

and Drawings).
prevents the assembling and fitting up of the parts by the proper use of these
drifts, shall be investigated immediately, As all work, is rigidly inspected in the
manufacturers workshop before despatch, these difficulties should not arise and
the cause should be first be sought In the use of incorrect components or the
transposition of a correct part. It isusually important that parts should be correctly
handled. Should error still persist, the matter shall be immediately reported to the
Engineer in charge who will decide what action is to be taken. No reaming shall be
undertaken without the written authority of the Engineer in charge, except for the
under drilled holes meant for turned bolts. If approved, the Contractor shall supply,
at his/her own expense, any special rivets that may be required. Copies of all
correspondence relative to the recourse to reaming and the use of over-size rivets
shall invariably be sent by the Engineer in charge for information to the inspector
at concerned.
Joints shall normally be made by filling not less than 50% of the holes with service
bolts and barrel drifts in the ratio of four to one. The service bolts are to be fully
tightened up as soon as the joint is assembled.
Special methods of erection other than described in Appendix III In cases where
the joints have to withstand stresses arising from special method of erection,
provision isto, be made to take the whole stress that will or may occur. Cylindrical
drifts and turned bolts shall be used to withstand such stresses and no reliance is
to be placed on the service bolts for this purpose. Upto maximum of 40% of the
holes of each memberof the joint are to be filled with drifts and balance of strength
required, is to be attained with turn bolts. The position and number of the (trifts
and bolts will be intimated by the Engineer in charge. The 'condition of clause 20.1
must be observed and the boltf ully tightened up as soon as the joint is made.
Where the manufacturing of girders has been done in accordance with clause 33
relating-to steel girder bridges, the erection shall be done in accordance with
Appendix III. However, if the Contractor desires to adopt any other method of
erection, tie/she shall submit the scheme and obtain the approval of the Engineer
in charge. It shall be ensured that when in position; the girder has the camber as
per drawing.
Emergency Jointing: -In the event of an emergency arising such as the staging is
in danger of being carried away by floods before the rivetting can be completed,
the joints shall be made secure by filling 40% of the holes with cylindrical drifts
and equal number with service bolts fully tightened.
4.9 Erection and Equipment

The Contractor shall provide at his/ her own cost all tools, machinery, equipment
and erection material necessary for the expeditious execution of the work and
shall erect the structural steel and iron work, in every respect as covered by the
contract and in accordance with the drawings and specifications,
If any labour, material, plant staging haulage and storage facilities are to be
provided by the Employer / Engineer details of such items and the conditions
Bidder 139 KDMC

and Drawings).
under which these are to be supplied shall be clearly specified, in the contract
agreements.
In the absence of any such provisions in the agreement, the Contractor shall
make his/ herown, arrangement for such items.
Before starting the work, the Contractor shall advise the Engineer in charge fully
as to the method he/ she, proposes to follow and the amount and character of
equipmenthe/she proposes to use, which shall be subjected to the approval of the
Engineer in charge. The approval of the Engineer in charge shall not be
considered as relieving the Contractor of the responsibility for the safety of his/her
method or equipment or from carrying the work in full accordance with the
drawings and specifications.
All temporary work shall be properly designed and substantially constructed for
the loads, which it will be called upon to support. Adequate allowance and
provision of all lateral forces and wind 'loads shall be made according to local
conditions and ensurethat support shall not settle during erection.
Careful and periodical inspection of plants shall be made by the Contractor to

ensure that all, tackle, ropes chains and other important lifting gear and machinery
are in good order and fit for service and well upto the capacity for which they are
required.
When chains are used for lashing, care must be taken to protect the edges of
members to avoid the marking and distortion otherwise caused.
Span erected upon staging shall be supported upon suitable blocks, which shall
ensure that the girders shall be at the correct elevation and alignment when
completed. If other methods of erection be adopted where staging in situ is not
employed special means shall be used to ensure this.
The method used for lifting and slinging flexible members shall be brought to the
notice of the Engineer in charge and shall be Subject to his/her approval.
Temporary bracing shall be provided to take care of stresses from erection

equipmentor other loads carried during erection.
Bidder 140 KDMC

and Drawings).
4.10 Bearings and Anchorages

Bed plates shall be set to required level and fixed accurately in position by giving
full and even bearing by setting them on a layer of cement sand and cast-iron
chips as approved and directed by the Engineer.
The Contractor shall drill the holes where necessary and set the anchor bolts. The
bolts shall be set accurately and fixed with cement grout or any other grouting
material as approved by the Engineer in charge completely filling the holes.
4.11 Rivets and Rivetting

The dimensions on the drawings referred to the diameters of the rivet holes and
the finished rivets. The rivet holes shall be 1.5 mm greater than the diameter of
the rivetars used, the rivets shall be made to IS:1929, The shanks of the undriven
rivets shall be made of a length sufficient to fill the holes thoroughly and form the
head. The clearance i.e. the difference in diameter between the rivets measured
under head before being heated and the rivet hole shall not be less than 0.75mm.
Before riveting is commenced all works shall be properly bolted so that the
sections rivetted are in close contact throughout. Rivets shall completely fill the
holes and shall be machine driven by means of pressure or percussion rivetters of
approved design.
All rivets shall be properly heated to straw heat for the full length of the, shank,
firmly backed and closed. The head of the rivet, particularly in long rivets, shall be
heated more than the point and in no case shall the point be heated more than the
head. Sparking or burnt rivets shall not be used. Where it is impossible to back up
by normal method of holding up double gunning may be resorted to. Alternatively,
pneumatic holding device may be used.
Gauges for rivet dimensions and contours shall be provided by the Contractor for
the use of the Engineer in charge / his representative.
Rivets when driven shall completely fill the holes, have the heads concentric with
the shanks and shall be in full contact with the surface. Driven rivets when struck,
sharply on the head with the 110-gm. rivet testing hammer, shall be free from
movement or vibration.
While rivetting bunt-up members reat care should be exercised to ensure that the
set of holes for field rivets in each flange of the built-up member, is aligned dead-
square inrelation to that in the other flange and not ‘aborrated’. Use of assembly
fixtures shall be made to ensure this.
All loose and burnt rivets and rivets with cracks badly formed, eccentric or
deficient heads shall be cut out and replaced. Permissible deviation of driven
rivets shall be as per Appendix-IV. Rivets shall also be cut out when required for
the examination of the work. Actual method of cutting out shall be approved by the
Engineer in charge. Recupping and caulking shall in no circumstances be resorted
to.
Bidder 141 KDMC

and Drawings).
Rivetting shall not be started until such time as the Engineer in charge has
personally satisfied himself that the alignment of the girders is correct, the
verticals plumb laterally, the camber according to that shown on the camber
diagram with camber jacks screwed tight, all the joints and cover plates well up,
service bolt tightened field rivet holes coinciding. Special care should be taken
that service bolts are frequently re-tightenedas the rivetting proceeds.
All field rivets shall be tested as directed by the Engineer in charge.
Where practicable all rivetting shall be done by pneumatic or hydraulic riveting

machine. The working pressure to be employed when using pneumatic or
hydraulic tools shall be approved by the Engineer in charge. Hand rivetting shall
only be done when sanctioned by the Engineer in charge. In such cases means
shall be adopted to ensure the rivets being used in their entire length so as to fill
the rivet holes completely, the snap being used only to give the correct form of
head.
When all the rivets of joints have been finally passed, they shall be painted with
one coat of ready mixed zinc chrome rimer to 18:104 followed by one coat of
readmixed paint red oxide zinc chrome primer to 15:2074 or as other primer
directed by the Engineer. Finishing coat shall be given with paint as decided by
the Engineer.
4.12 Field Rivets, Bolts, Nuts· and Service Accessories

The work is to include supply of all units, bolts, nuts, washers etc. required to
complete erection at site with an allowance for wastage etc. of 12.5% of the net
number of field rivets, bolts and washers required subject to a minimum number of
five in each item.
The Contractor shall be responsible for supplying site rivets of approved length.
The length of such rivets shall be verified by snapping a few rivets of each length
in the presence of the Engineer in charge / his representative. In the case of rivets
with long grips (with grip exceeding 6 times the diameter) specimen rivets on the
test piece shall be cut to see if the holes are totally filled even though the rivets
are tight under the usual hammer tests.
Black hexagonal bolts (Service bolts) with nuts and ordinary platter's washers an
drifts for use in the erection of the work shall also be supplied at 60% (45% bolts
and 15% drifts) of the number of field rivets per span in each size (this includes
wastage). The Employer / Engineer in charge may however, specify a reduction in
the quantities of servicebolts etc. if more than one span of each type is ordered.
Bidder 142 KDMC

and Drawings).
4.13 Smithed Work

All joggles shall be performed by pressure, Craned sections or knees can be
formed by forging or by gas cutting and, Welding by any approved electric arc
process, Any bending, forging, cutting or welding shall be carried out in such a
manner as not to impair the strength in the metal. Forging shall be annealed as
Indicated in the drawing.
If drop forging through dies is resorted to, excessive forging in one Operation shall
be avoided. Where necessary, a series of intermediate stage dies shall be
manufacturedand used.
4.14 Welding
Weilded construction work shall be carried out generally in accordance with the
provisions of Indian Railway Standard Welded Bridge Code and subject to further
specifications given in the following paragraphs.
All welds should be done by submerged arc welding process either fully automatic
or semi-automatic. Carbon dioxide welding or manual metal arc welding only be
done only for welds of very short runs or of minor importance or where access of
the locations of weld do not permit automatic or semi-automatic welding.
Except for special types of edge preparation, such as single and double ‘U’ single
and double 'J' the fusion edges of all the plates which are to be joined by welding
may be prepared by using mechanically controlled automatic flame cutting
equipment and then ground to a smooth finish. Special edge preparation should
be made by machining or gouging.
Welding procedures: -The welding procedure shall be such as to avoid distortion

and minimize residual shrinkage stresses. Properly designed jigs should be used
for assembly. The welding techniques and sequence, quality, size of electrodes.
voltage and current required shall be as prescribed by manufacturers of the
material and welding equipment. The Contractor should submit full details of
welding procedure in proforma given at Apppendix V.
Site welding should not be undertaken except in special circumstances with the
approval of the Engineer in charge. Site welding should be confined to
connections having low stresses, secondary members. bracings etc.
Manual metal arc welding may be done taking adequate precautions as per
IS:9595 and under strict supervision.
4.15 Sequence of' Welding Pass

For fabrication of welded composite girders channel shear connectors shall be
weld on top flange plate prior to assembly of I-section. This facilitates correction of
Bidder 143 KDMC

and Drawings).
any distortion of flange plate developed during the welding of channel shear
connectors.
In making a typical I-section four fillet welds are to be made. The welding
sequence to be followed is indicated by number 1 to 4 as shown in the Fig. 3.
Whenever a square butt weld in a 10 or 12mm thick plate is required to be made.
the. sequence to be adopted is shown in Fig. 3.
4.16 Bolts, Nuts and Washers
Bolts, Nuts and Washers shall be in accordance with the following specifications:
Black hexagonal bolts to IS:6639 and Nuts to IS:1363.
Precision and turned bolts with nuts and hexagonal screws to IS:1364.
Plain washers to IS:2016 and IS:5369.
Spring washers -IS:3063.
Taper washers -IS:5372 and IS:5374.
Manufacture, workmanship, Marking, packing etc. for Bolts and Nuts shall comply
with the requirements of IS:1367.
Where the head and nuts bear on timber. square washers having the length of
each side not less than three diameters of the bolt and the thickness not less than
one quarter of the diameter, shall be provided. Steel wrought iron or malleable
cast iron taper washers shall also be provided for all heads and nuts bearing on
bevelled surfaces.
For black (service) bolts a clearance (difference in diameter) of 1.5mm for all sizes
of bolts shall be allowed.
Where turned bolts are required, they shall be carefully turned and shall be
parallel, through out the barrel. Holes for turned bolts should be 1 mm under-
drilled in shopand should be reamed at site to suit the diameter of the turned bolts.
The following limits of tolerances shall be permitted upon the diameter of the
shank of turned bolts arid, of the holes which they are to fit:
Limit of tolerance Shank of bolt (mm) Hole (mm)
High 0.000 +0.125
Low –0.125 0.000
The shank of each turned bolt shall be of such a length that it is in full contact with
the work, throughout, the screwed portion being made at least 1.5mm less in
diameter than the shank or to suit the next smaller size of screw thread. The
shank portion shall be joined to the threaded portion by a 45° chamfer within the
thickness of the washer. Washers with perfectly flat faces should be provided with
all turned bolts.
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and Drawings).
The washers under the nut shall have a hole of 1.5mm larger in diameter than the
shank of the bolt and shall have a thickness of not less than 6mm so that the nut.
When screwed up, shall not bear on the shoulder of the bolt.
4.17 Connecting Pins

All connecting pins shall be finished accurately to gauge and parallel throughout.
straight and with smooth surface entirely free from flaws and of sufficient length to
ensure that, all parts connected thereby shall have a full bearing on the pin. They
shall be turned. to a smaller diameter at the end for the thread and driven to place
with a pilot nut where necessary to preserve the thread.
4.18 Pin Holes
Pin holes shall be bored smooth straight and true to gauge and at right angles to
the axis of the member. Boring shall only be done after the member has been
rivetted upand the diameter of the pin shall not be less than that of the hole by
more than 0.5mm.
4.19 Bearing and Expansion Gear

All steel bed and bearing plates or plates over saddle castings; shall be made
perfectly level and all rivet heads on their bearing surfaces shall countersunk and
dressed flush.
The saddles knuckle-bearers and roller bed-plates shall be planed on all bearing
surfaces and elsewhere as indicated on the Contract Drawings and all bolt holes
shall be drilled. The bottom edge of ribs should be machined and welded to the
bottom slabs after which the top edges of the ribs should be machined as a whole
and top plate welded. Subsequently the top and bottom surfaces should be
machined to specified tolerances as given in appendix VI. Generally, in
connection with bearing gear all meeting surfaces including the sides of the roller
frames, shall machined, all bolts except anchor bolts d and fitted, all washers
faced, the knuckles and pins polished to smooth surface end the whole finished in
the style of first class machined work.Tolerances shall be as specified in Appendix
VI and shall be shown on the drawings.
4.20 Erection in Contractor's Works

The work shall be temporarily erected complete at the Contractor’s work for
inspection by the Engineer in charge/ his representative, with the exception of
such riveting as has to be done at site, so that accuracy of fit and perfection of
workmanship may be assured. The work shall be put together with sufficient
numbers of parallel drifts or turned bolts or both to bring the ieces into place.
When so erected all holes left to be filled at site shall be so fair that a parallel
gauge turned to a diameter 0.8 mm less than that of the hole, of a length equal to
the depth of the hole, can be passed through them without difficulty. No drift shall
be used anywhere in the work larger in any part than the hole in which it is to be
Bidder 145 KDMC

and Drawings).
driven. Holes for turned bolts, which have been 1mm under-drilled in shop, should
be reamed at site by the erecting agency.
4.21 Interchangeability
Every span is to be temporarily erected complete in Contractor's works adopting
the method of giving camber as explained in clause 34 and all parts as marked to
their place, unless the whole of the work is made completely interchangeable by
the use of steel jigs and hard steel bushes controlled by master gauges, in which
case the first span must be completely erected to test the accuracy of the
templates. Further spans or part span assemblies built from parts selected at
random by the Engineer in charge / his representative shall be erected from time
to time to check the accuracy of the work as the Engineer / his representative may
require. If the work is considered interchangeable by the Engineer in charge / his
representative a simplified scheme of marking will be permitted, i.e., all pieces
which are identical shall be a one distinguishing mark irrespective of the span to
which they belong. Should the interchangeability not to the satisfaction of the
Engineer in charge / his representative, the whole of the spans must be erected
complete and an parts marked to their place without additional charge. The
tenderers must state in their tenders whether they intend to adopt complete
interchangeability or not.
Under special arrangement with the Employer / Engineer in charge, it shall be

permissible for approved portions of the work to be dispatched before complete
erection of the firstspan, provided the Contractor satisfies the Engineer in charge /
his representative that Such portions of the work are strictly interchangeable and
will assemble correctly and accurately in the complete structure.
4.22 Camber
In order to ensure that the fabrication and erection of main girders shall be such
as to eliminate secondary stresses in the loaded span, the nominal length (i.e. the
lengths which will give no camber) of member shall be increased or decreased by
the amount shown on the camber diagram supplied by the Employer / Engineer in
charge.
For setting of the angles of intersection of the chords and web members and also
for templating the gusset, full size of panels with nominal lengths of the members,
shall be used. Similarly, the machining of all chords butts shall be to suit the
nominal outline as defined in clause No. 34.1.
The procedure for erecting, the span at Contractor's work shall be as specified.
The site rivetting holes shall be rivetted or bolted and drilled as specified in
Appendix III.
Bidder 146 KDMC

and Drawings).
When supported, on blocks or stagings, the girders shall be erected to the camber
specified in the fabrication drawings according to which the girders have been
manufactured. A camber diagram indicat in the relevant height of each panel point
when erected on blocks at the manufacturing works shall be supplied by the
Engineer.
The cambering of the main girders along with pre-stressing, when all panel points
are supported on the blocks or staging shall be carried out in accordance with
Appendix 'A' of Steel Bridge Code.
Special methods of erection, such as cantilever erection or erection by floatation,

will require special erection drawings approved by the Engineer in charge, which
must not be deviated from.
In the case where the girders are erected on yielding supports such as a 16
service span, due allowance shall be made for the anticipated yield when the
camber blocksare set out.
Frequent checks shall be made of the camber of girders during erection and care
taken to see that the camber as per drawing is obtained when the girder is
completely assembled. When span is supported on ends and intermediate
supports are removed the dead load camber shall be recorded and entered in
bridge register. This will, provide the reference to compare the camber checked
during technical inspection to ascertain the loss of camber.
4.23 Testing
The Engineer in charge / his representative shall be empowered, at his/ her
discretion to make or have made under the supervision, any of the tests specified
in the specifications mentioned herein in addition to such other tests as he/she
may consider necessary at any time upto the completion of the contract and to
such an extent as he/ she may think necessary to determine the quality of all
materials used therein. In doing so, he/she shall be at liberty any reasonable
procedure he/ she may think fit to select, identify, have cut-off and take
possession of test pieces from the material either before during or after its being
worked up into the finished product.
He shall also be empowered to call for a duly authenticated series of mechanical

tests to be obtained from the maker for this material used in the work and to
accept the same in lieu of other tests to the extent he/she deems fit. The
Contractor shall supply the material required for the test pieces and shall also
prepare the test pieces necessary.
The test shall be carried out by the Contractor, for which Contractor shall provide
all facilities including supply of labour and plant. Engineer in charge / his
representative may at his/ her discretion direct the Contractor to despatch such
tests pieces as he/ she may require to the National test House or elsewhere as
he/ she may think fit for such testing purposes.
Bidder 147 KDMC

and Drawings).
4.24 Check on Tests Made at Contractor’s Work

The Engineer in charge / his representative may at his/ her discretion, check test
results obtained at Contractor’s work by independent tests at National test House.
The Engineer in charge / his representative shall at all times be empowered to

examine and check the working of the Contractor’s plant before and after using it.
Should the Contractor’s plant be found in the Engineer in charge / his
representative’s opinion, unreliablehe/ she is empowered to cancel any tests
already carried out in this contract and haveTest House or elsewhere, as he/ she
may think fit.
4.25 Analysis
The Contractor shall supply authenticated copies of analysis of any materials used
in the contract when required to do so by the Engineer in charge / his
representative who shall be empowered to accept them to the extent he/ she
thinks fit. In addition to the above samples may at the Engineer in charge / his
representative’s discretion be subjected to complete analysis at the National test
House or elsewhere as the Engineer in charge / his representative may determine
the cost of the same to be borne by the Employer.
4.26 Inspection – General

The Engineer / his representative shall have free access to the works of the
Contractor at all reasonable times and shall be at liberty to inspect the process of
manufacture at any such time and to reject in whole or part, any work or material
that does not conform to the provisions of this Specification and may order the
same to be removed, replaced or altered at the expense of the Contractor. All
gauges and templates necessary to satisfy the Engineer in charge / his
representative of the complete interchangeability of parts must be supplied by the
Contractor free of cost.
4.27 Erection Mark

Every portion of the work shall be distinctly stencilled with paint with letter size not
less than 10 mm for guidance in the erection in the field, and stamped with the
letters specified in the drawings. In the case of non-interchangeable work, the
system of marking shall be in accordance with the drawings prepared by the
tenderer and approved by the Employer
4.28 Weight of Steelwork for Payment

Payment shall be made on the tendered weight to be calculated in accordance
with the nominal weight of the sections as specified on the contract drawings. An
addition in weight for welds and rivet heads should either be specified in the
schedule or be made as follows:
Bidder 148 KDMC

and Drawings).
a. 3% in case of rivetted or composite (rivetted and welded) work; and

b. 1% in case of purely welded work.
Gusset areas shall be calculated on the basis of minimum enveloping rectangle
and skew cuts will be considered as containing rectangle for purposes of
calculating weights.
4.29 Rivet and Bolt Lists

The Contractor shall also supply, without charge, three complete lists of the rivets,
bolts, service bolts, washers and drifts required for erecting the work at site,
showing the parts of the work to which, the various rivets and bolts belong and
having each item marked so as to indicate the particular case in which it will be
found.
5. Supplementary specifications for steel works
i. For all the works, workmanship shall be of first-class quality, throughout, in

conformity with IRS B1-2001 or latest edition, and true to line, level and dimension
as shown in the drawings or instructed by the Engineer in charge.
ii. All parts assembled for bolting shall be in close contact over the whole surface
and all bearing stiffeners shall bear tightly at top and bottom without being drawn
or caulked. The component parts shall be so assembled that they are neither
twisted nor otherwise damaged as specified cambers if any shall be provided.
Drilling done during assembling shall not distort the metal or enlarge holes. The
butting surfaces at all joints shall be so cut and milled so as to butt in close
contact throughout the finished joints.
iii. Cutting shall be done automatically. Hand flame cutting will not be permitted.
iv. The edges and ends of all cut/sheared flange plates, web plates of plate girders,
and all cover plates, and the ends of all angles, tees, channels and other sections
forming the flanges of plate girders, shall be planed/ground.
v. Holes for bolts shall be drilled to conform to clause 10 of IS : 7215
(1974).Punching of holes will not be permitted. All drilling shall be free from burrs.
No holes shall be made by gas cutting process.
vi. All welding for the works shall be carried out by first class welders and shall bein
accordance with IS : 816, IS : 819, IS : 1024, IS : 1261, IS : 1323 and IS : 9595.
The Engineer in charge may at his discretion order periodic tests of the welder
and/or of the welds produced by them. All such tests, shall be carried out by the
Contractor at his cost.
vii. Safety requirements should conform to SP:70, IS : 7205, IS : 7273 and IS : 7269
as applicable and should conform to safety, economy and rapidity.
viii. As much work as possible shall be welded in shops. The pieces shall be
manipulated to ensure down hand welding for all shop joints as far as possible. All
parts to be welded shall be arranged so as to fit properly on assembly. After
Bidder 149 KDMC

and Drawings).
assembly and before the general welding is to commence the parts are to be tack
welded with small fillet or butt welds as the case may be. The tack welding must
be strong enough to hold the parts together but small enough to be covered by the
general welding. The welding procedure shall be so arranged that the distortion
and shrinkage stresses are reduce to a minimum.
ix. All joints required in structure to facilitate transport or erection shall be shown on
the drawings or as specified by the Engineer in charge. Should the Contractor
need to provide joints in locations other than those specified by the Engineer in
charge he shall submit his proposals and obtain the prior sanction of the Engineer
in charge for such joints. The lengths of structural shall be the maximum normally
available in themarket jointing of shorter length in order to make up lengths
required shall not be permitted.
x. Each piece of steel work shall be marked distinctly before delivery, indicating the
position and direction in which it is to be fixed. Three copies of a complete
marking plan are to be supplied to the Engineer in charge before erection
commences.
xi. In the case of welded fabrication any distortion remaining in the member afte
rwelding operations are completed shall be rectified by and/or at the expense of
the Contractor to the approval of the Engineer in charge.
xii. All members of trusses and lattice girders shall be straight throughout their length,
unless shown otherwise on the drawings, and shall be accurately set to the lines
shown on the drawings. Sheared edges of gussets or other members tobe
straightened and dressed where necessary.
xiii. Templates and jigs used throughout the work shall be all steel. In cases where
actual materials have been used as templates for drilling similar pieces, the
Engineer in charge shall decide whether they are fit to be used as parts of the
finished structure.
xiv. Apart from the requirements of welding specified under the above sub clauses,
sections above, the Contractor shall ensure the following requirements in the
welded joints.
a) Strength-quality with parent metal.
b) Absence of defects
c) Corrosion resistance of the weld shall not be less than that of parent
material in an aggressive environment.
xv. No gasket or other flexible material shall be placed between the holes. The holes
in parts to be joined shall be sufficiently well aligned to permit bolts to be freely
placed in position. Driving of bolts is not permitted. The nuts shall be placed so
that the identification marks are clearly visible after tightening. Nuts and bolts shall
always be tightened in a staggered pattern and, where there are more than four
bolts in any one joint, they shall be tightened from the centre of the joint outwards.
Bidder 150 KDMC

and Drawings).
6. Testing of Welds
i) Butt welds -Radiographic testing of 50% of welds as per IS 1182.
ii) Fillet welds -Ultrasonic testing of 10% of welds.
iii) All welded connections shall be inspected as per IS:822
iv) All welds shall be tested by "dye penetration test".
v) Agency for testing of weld shall be approved by the Engineer in charge prior to
testing.
vi) Defective welds shall be repaired or replaced as decided by the Engineer in

charge. There paired or replaced welds shall be tested using the same methods
as above. Additionally, when defective welds are found, the cause of the defective
welding shall be determined and the contractor shall institute immediate corrective
action.
vii) No extra payment shall be made for the tests indicated above.
7. Protection of Steel Works (IS : 8629):

i) Sand blasting where specified shall be carried out in accordance with IS : 1477.
ii) Painting work shall be carried out in accordance with IS : 8629 (Parts I to
III)Painting gg shall be applied under the temperature requirement specified by the
manufacturer.
iii) The steel work, prior to delivery, shall be cleaned form scale, rust, dirt and oil
/grease etc., but means of chipping, scraping and wire brushing using skilled
operators as described in the painting systems below. The cleaning shall proceed
each day over the extent of surfaces which can be painted on that day. The paint
shall be applied by brushing or spraying as per approval of theEngineer in charge.
iv) Paint brushes round/oval and flat shall be conforming to IS : 487 and IS : 384
codes respectively, if painting with brushing is approved by Engineer in charge.
v) The spraying equipment shall be compatible with the paint material, fitted with
necessary gauges and controls and approved by the Engineer in charge.
vi) Site weld locations shall be left free from paint within 50 mm of the weld position,
and contact surfaces in connection using High Strength Friction Grip Bolts shall
not be painted. Immediately after completion of erection all damaged paint shall
be scraped off and made good to the approval of the Engineer in charge.
vii) The workmen shall also clean down and apply one coat of primer to all site bolts,
site bolted connections and site weld locations and the paint work generally shall
be left in sound condition for any subsequent painting.
Bidder 151 KDMC

and Drawings).
viii) All paints and primers shall be of best quality and in original sealed containers as
packed by the paint manufacturer conforming to the relevant Indian Standards
and shall be procured directly from the manufacturers. All paint to be used shall
be stored under cover in such conditions as will preserve it from extreme of
temperature and the paint shall be used and applied strictly in accordance withthe
manufacturer's instructions.
ix) In addition, the following specification shall apply to the shop painting of contact
and in accessible surfaces:
a) Surfaces to be painted shall be thoroughly cleaned from scale, rust, dirt,
grease etc. by means of sand/grit/shot blasting or other equivalent means.
b) Surfaces which are to be brought permanently into close contact or made in
accessible either in the shops or upon erection shall, after cleaning, be given
two coats of Red Lead Priming Paint. The surfaces shall be brought into
contact while the paint is still wet.
c) Contract surfaces in connection using High Strength Friction Grip bolts shall
not be painted or oiled and shall be free from dirt, loosed scale, burrs, its and
any other defects which would prevent the solid seating of the parts and would
interfere with the development of friction between them.
d) All enclosed surfaces of box members shall be completely sealed by oiling or
by coating with approved bitumen paint and all such members and tubes shall
have their ends closed by suitable plates welded in position.
x) Surfaces in contact during shop assembly shall not be painted. Surfaces which
cannot be painted, but require protection, shall be given a rust inhibitive grease
conforming to IS:958 (1975), or solvent deposited compound conforming
toIS:1153 (1975) or IS:1674 (1960), or treated as specified in the drawings.
xi) Surfaces to be in contact with concrete shall not be painted.
8. Erection & Site Work

i. The Contractor shall be responsible for checking the alignment and level of
foundation and correctness of foundation bolt centres, well in advance of
starting erection work, and shall be responsible for any consequences for
non compliance there of. Discrepancies if any shall immediately be brought
to the notice of the Engineer in charge for his advice.
ii. The structure should be divided into erectable modules as per the total
scheme.This should be pre-assembled in a suitable yard/platform and its
matching with members of the adjacent module checked by trial assembly
before erection.
iii. Immediately prior to erection any rust in the paint area shall be removed by
power wire brushing to a standard equivalent to SA3.
iv. During erection the rough handling of fabricated materials such as
bending, straining or pounding with sl edges shall be avoided. Any
damage to the structure during transportation or erection shall be
Bidder 152 KDMC

and Drawings).
immediately rectified by the Contractor at his own cost. The straightening

of bend edges of plates, angles andother sections shall be done by
methods which will not cause fracture.
v. Following the completion of the straightening, the surface of the member
shall carefully be inspected for damage and got approved by the Engineer
in charge before further use.
vi. The Contractor shall be responsible for accurately positioning, leveling and
plumbing of all steelwork and placing of every part of the structure in
accordance with the approved drawings and to the satisfaction of the
Engineer in charge. All stanchion base, beam and girder bearings etc.
shall be securely supported on suitable steel packs. All reference and
datum points shall be fixed near the worksite for facilitating the erection
work.
vii. All equipment used by the Contractor shall be sufficient for the purpose
and for the erection of the steel work, in the time specified in the contract.
Any lifting or erecting machinery shall be to the approval of the Engineer in
charge and shall be removed from the site if he considers such appliances
dangerous or unsuitable for their functions. The approval of the Engineer
in charge shall not relieve the Contractor of the responsibilities for the
loads to which the erection equipment shall be calle upon to carry.
Adequate arrangement shall be made to resist wind loads and lateral
forces arising at the time of erection.
viii. The Contractor is entirely responsible for the safety and stability of the
structure during erection and shall arrange that sufficient tack bolts, braces
or guy ropesare used to ensure that work will remain rigid until final bolting,
riveting orwelding is completed. The Contractor shall supply and fix,
without extra charge, any temporary bracing which may be necessary.
ix. All steelwork shall be erected in the exact position as shown on the
drawings. All vertical members shall be truly vertical throughout and all
horizontal members truly horizontal, fabrication being such that all parts
can be accurately assembled and erected. No permanent bolting, welding
or grouting shall be done until proper alignment has been obtained and
checked by the Engineer in charge.
x. At stanchion splices and at other positions where concrete cover to the
steel is liable to be restricted; bolts will be placed with their heads on the
outside of the members.
xi. All field assembly bolting and welding shall be executed in accordance
with the requirements for shop fabrication excepting such as manifestly
apply to shop conditions only. Where steel has been delivered painted the
paint shall be removed before field welding for a distance of at least 50 mm
on either side of the joints. The number of washers on permanent bolts
shall not be more than two for the nut and one for the bolt head.
Bidder 153 KDMC

and Drawings).
xii. Only workmen experienced and skilled in steel erection shall be employed
for the work. The safety of the workmen as well as that of the structure is
Contractor’s prime responsibility.
8. Rectification of damaged materials

Any error in shop work which prevents the proper assembly and lifting up of the
parts by moderate use of drift ins or reaming or cutting shall be immediately
reported to the Engineer and his approval of the method of rectification obtained in
writing. Wrongly fabricated material whose erection in the field necessitates extra
work shall be the responsibility of the contractor. The entire costs of such
operation including there placement of defective members, if required, shall be
borne by the contractor.
9. Inspection
i. The contractor shall inform the Engineer in charge of the progress in
fabrication and as to when individual pieces are ready for inspection. All
gauge templates necessary to satisfy the Engineer in charge shall be
supplied by the contractor. The Engineer in charge may at hisdiscretion
check the results obtained at the contractor's works by independent tests
and should the material so tested be found unsatisfactory, the cost of such
tests shall be borne by the contractor.
ii. Structural steel and components viz. bolts, nuts, washers, welding
consumables, etc. should be tested for mechanical and chemical
properties as per the requirement of the relevant IS or any other specified
codes/standard.
iii. During Inspection, the component/member shall not have any load or
external restraint.
10. Grouting of steel bases
i. Before grouting of stanchion bases, the contractor shall take the following
action:
a) Inform the Engineer in charge.
b) Clean all holes, openings, recesses and the top of foundations of
all dirt, mud, water, oil or other extraneous matter.
c) A frame shall be placed in position around the base plate with a
provision for placing or injecting grout.
d) The contractor shall provide screed bars or mild steel flats and fix
them in mortar.
e) Holes shall be provided on the stanchion bases for escape of air.
ii. Grouting of steel beams, steel stanchions, bases and bearings and
encasement of steelwork will be carried out by the contractor after the
Bidder 154 KDMC

and Drawings).
steelwork has been finally aligned and leveled and approval of the
Engineer in charge obtained.
iii. The bolt sleeves shall be grouted as a separate operation using neat
cement grout of a creamy consistency, which shall be poured in so as to
completely fill the holes. "Non-shrink" cements, additives of approved
makes shall be used forall grouting operations.
iv. The space between the top of the foundations and the underside of the
base plate shall be completely filled with a mix 1:2 cement sand mortar
and finished flushwith edge of the base plate, either:
a) Mixed as a stiff mortar well rammed into place from all sides.
b) Mixed as thickly as possible consistent with fluidity and poured
under a suitable head and tamped until the space has been
properly filled.
11 Holding down and Anchor bolts
i) The holding down and anchor bolts should conform to the requirements
laid down in IS:5624 or as directed by the Engineer in charge.
ii) Installation: Individual bolts in groups of holding down bolts shall be

positioned accurately within a tolerance of +6mm. The bolts shall be set
vertically to a tolerance of not more than 1 in 250.
iii) During the casting of concrete, the contractor shall ensure that space
between the bolt and sleeves is kept clean after removal of shuttering. The
contractor shall provide and fix timber plugs to maintain this space in a
clean condition. The projecting threads of bolts shall be protected by
approved wrapping materials.
iii) Grouting of bolt tubes shall be carried out after the steelwork or equipment
have been aligned, plumbed and leveled.
Bidder 155 KDMC

and Drawings).
12 Tolerances
i. All tolerances shall be in accordance with IS: 7215 unless otherwise
specified.
ii. The maximum deviation for line and level shall be + 3.0mm for any part of
the structure including for location of column centres.
iii. The maximum deviation from plumb for columns shall be +3.0mm in 10.0m
height subject to a maximum of +6.0mm in a total height of 30.0m.
iv. The deviation at the centre of the upper chord member from vertical plane
running through the centre of the bottom chord shall not be more than
1/1500 of span but in no case more than 10.0mm. The lateral
displacement of top chordat centre of span form vertical plane running
through centre of supports shallnot be more than
1/250 of the depth of truss but in no case more than 20.0mm.
a. No sub-punching shall be allowed in the main truss' members of open web
Bidder 156 KDMC

and Drawings).
Bidder 157 KDMC

and Drawings).
Bidder 158 KDMC

and Drawings).
Bidder 159 KDMC

and Drawings).
CLAUSE SP-13 ENVIRONMENTAL MANAGEMENT PLAN

The Contractor shall implement the EMP measures, enhancement measures and
measures as directed by KDMC/PMC. The contractor shall submit a report on
compliance with the environmental mitigation measures (Environmental
Compliance Reports, ECRs) periodically to the PMC. The PMC will review and
approve the ECRs submitted by the Contractor. After approval, the PMC will
forward the ECR to KDMC.
Bidder 160 KDMC

Name of Work: Construction of Approaches to proposed R.O.B. in lieu of level crossing gate no.51 at Km. 63/21-22 on KYN-IGP section between
Ambivli & Titwala railway stations (Manda - Titwala R.O.B.) (With contractors own Design and Drawings).
TABLE 1 - PRE-CONSTRUCTION STAGE EMP FOR PROJECT

Environ Mitigation Measures Cross Time Responsibility
mental Reference to Frame Implementation Supervision
Issue Documents
Utility All utilities to be shifted after prior M/ORT&H 110 Before start of Contractor PMC/KDMC
relocation approval of agencies. Utility relocation construction of relevant
shall be carried out in the shortest section
possible time to reduce
inconvenience to public. Prior
approval of the concerned utility
agencies to be obtained by
Contractor.
Impact on Construction related activities shall be M/ORT&H 201.2 During entire site Contractor PMC/KDMC
land use preferably restricted within project clearance and
outside road ROW. construction phases
ROW
Ecological Trees falling within the alignment Preservation of Tree Before start of Contractor PMC/KDMC
impacts which are to be removed before Act of Maharashtra, construction of relevant
due to tree commencement of construction shall 1975 section
cutting be identified and approved by PIA.
Prior permission from respective
authority/Tree authorities shall be
obtained by the Contractor.
Local Temporary traffic arrangement during M/ORT&H 112 Clearance and Contractor PMC/KDMC
Traffic construction shall be periodically construction
Arrangem reviewed with respect to site
ent conditions. During site clearance
activity, the demolition debris shall be
preferably removed during non-peak
hours and with deployment of more
vehicles for the purpose.
Bidder 161KDMC

Issue Documents
Traffic The Contractor shall take all M/ORT&H: 112.4 During preconstruction Contractor PMC/KDMC
Control necessary measures for the safety of M/ORT&H: 112 and construction
And Safety traffic during demolition and site
clearing activities.
He shall provide, erect and maintain
such barricades, including signs,
markings, flags, lights and flagmen as
may be required by the PMC for the
information and protection of traffic
Safety of Special consideration shall be given M/ORT&H: 112.2 Before construction and Contractor PMC/KDMC
Pedestria in the local traffic management to the during construction
ns safety of pedestrians
Bidder 162KDMC
TABLE-2 - CONSTRUCTION STAGE EMP FOR THE PROJECT

Issue Documents
Plying vehicles on The unpaved roads, if used by the M/ORT&H: 111:10 Construction Contractor PMC/KDMC
unpaved roads Contractor, shall be sprinkled with Phase
water at least once in a day to control
the fugitive dust emissions.
Material Spill All vehicles delivering material to the M/ORT&H: 111.9 Entire Construction Contractor PMC/KDMC
site shall be covered to avoid material M/ORT&H: 111.11 Phase
spillage M/ORT&H: 111.12
Using existing hot It is understood from the implementing M/ORT&H: 111.5 During Entire Contractor PMC/KDMC
mix/Concrete/As phalt authorities, that the Contractor will Construction
Plants utilize the existing Concrete, Asphalt Phase
and Hot Mix Plants. Contractor shall
ensure that existing plants, which are
sourced, are licensed and authorized
for operation by concerned authorities
and shall intimate the PMC/PIA prior
to procuring materials from them. PMC
shall procure relevant documents from
the plant owners to ensure that they
are adhering to relevant emission
norms as laid out by MOEF/CPCB
Watering to control Construction site to be watered M/ORT&H: 111.8 During entire Contractor PMC/KDMC
dust at site periodically to minimize fugitive dust construction Phase
generation
Bidder 163KDMC

Issue Documents
Roads used for Contractor shall ensure that the M/ORT&H: 111.9 During entire Contractor PMC/KDMC
transport transport vehicles used to ferry construction Phase
materials and dispose debris does not
create hazardous conditions for
general traffic using the roadway
Barricading site The construction site should be M/ORT&H: 112 During Contractor PMC/KDMC
barricaded at all time in a day with Construction
adequate marking, flags, reflectors Phase
etc., for the safety of general traffic
movement and pedestrians
Earthwork All earthwork and construction M/ORT&H 201.4 During entire Contractor PMC/KDMC
material should be stored in such a construction phase
manner to minimize generation of dust
and spillage on roads.
Idling of vehicles Idling of delivery trucks or other M/ORT&H 201.2 During Contractor PMC/KDMC
equipment should not be permitted Construction phase
during periods of unloading or when
they are not in active use. This
practice must be ensured especially
near sensitive receptors like places of
worship.
Drilling Operations All possible and practical measures to M/ORT&H 111 During Contractor PMC/KDMC
control noise emission during drilling Construction
operations shall be employed. The Phase
PMC may direct to take adequate
control measures depending on site
conditions.
Bidder 164KDMC

Issue Documents
Construction Exhaust and noise emissions of Legal requirement During Contractor PMC/KDMC
equipment emissions construction equipment shall adhere to Construction
emission norms as laid out by
MoEF/CPCB.
Noise from All construction equipments shall be M/ORT&H: 111 During Contractor PMC/KDMC
construction related fitted with exhaust silencers. Damaged Construction
plants & equipments. silencers to be promptly replaced by
Contractor.
Noise impact due to DG sets, if used, shall adhere to noise M/ORT&H: 111 During Contractor PMC/KDMC
operation of DG sets standards of MoEF Construction
Noise level near Construction activity induced noise M/ORT&H: 111 During Contractor PMC/KDMC
residential areas and levels shall be mitigated between km. Construction of
sensitive receptors The Contractor can employ mitigation relevant sections
measures such as restricted and/or
intermittent activity or as directed by
PMC.
Noise due to Operation hours for noise generating During Contractor PMC/KDMC
foundation works at equipments such as pile driving, Construction
flyover and concrete and drilling, etc. shall be
ROB/Viaduct preapproved by PIA. The PIA
depending upon site conditions and as
per prevailing local laws may regulate
and/or restrict operation hours.
Exposure to Loud Workers exposed to loud noise (As M/ORT&H: 111.6 During Contractor PMC/KDMC
Noise per Factory Act requirements) shall M/ORT&H: 105.2 Construction
wear earplugs/earmuffs
Bidder 165KDMC

Issue Documents
Construction of new The drains shall be cleared off all MORT&H: 306 During Contractor PMC/KDMC
roadside drains construction debris before handing M/ORT&H: 309 Construction
over to employer.
Soil Erosion On road embankments, slopes shall M/ORT&H: 306 During Contractor PMC/KDMC
be stabilized. The work shall consist of Construction
measures as per design, on as
directed by the PMC to control soil
erosion, sedimentation and water
pollution.
Siltation of water Siltation of soil into water bodies viz., M/ORT&H During Contractor PMC/KDMC
bodies River, Nallah/Drain, shall be prevented Guidelines 305 Construction
as far as possible by adopting soil through 309
erosion control measures as per M/O
RT&H guidelines / or as per the
directions of PMC
Foundation excavation Bentonite slurry or similar debris Project requirement During Contractor PMC/KDMC
debris generated from pile driving or other Construction
construction activities shall be
disposed such that it does not flow into
surface water bodies.
Work during monsoon Construction work at sections close to Project requirement During Contractor PMC/KDMC
near water bodies water bodies shall be avoided during Construction
monsoon or completed before
monsoon.
Inspection of site Daily inspection at construction site M/ORT&H 301.3 During Contractor PMC/KDMC
should be carried out to ensure Construction
removal of construction debris Phase
Bidder 166KDMC

Issue Documents
Earthwork debris As soon as construction is over the M/ORT&H 301.3 During Contractor PMC/KDMC
disposal surplus earth should be utilized to fill Construction
up low-lying areas or the dumping Phase
area identified by KDMC In no case,
loose earth should be allowed to pile
up along alignment.
Earthwork debris As soon as construction is over the M/ORT&H 301.3 During Contractor PMC/KDMC
disposal surplus earth should be utilized to fill Construction
up low-lying areas or the dumping Phase
area identified by KDMC In no case,
loose earth should be allowed to pile
up along alignment.
Debris Disposal Debris generated due to dismantling of M/ORT&H 301.3 During Contractor PMC/KDMC
existing pavement/structures shall be Construction
suitably reused in proposed
construction. Un-utilizable debris shall
be suitably disposed at the site
identified by the PMC/KDMC. Good
disposal practices recommended by
various agencies/authorities shall be
followed.
Soil contamination by Oil and fuel spills from construction Project requirement During Contractor PMC/KDMC
construction wastes, equipment shall be minimized by good Construction
fuel etc O & M practice. Soils contaminated by
such spills shall be disposed as per
MoEF
Bidder 167KDMC

Issue Documents
Sourcing Quarry Sand, aggregates and other M/ORT&H During Construction Contractor PMC/KDMC
Materials quarry material shall be sourced 111.3
from licensed quarries. DPR has
identified few quarries viz. in the
region for sourcing the material
Providing Labour The Contractor shall abide by the M/ORT&H During Construction Contractor PMC/KDMC
camps and Contract conditions and directions 105.2
facilities of PMC/PIA with respect to siting
of labour camps, providing
sanitation facilities and labour
welfare issues etc.
Occupational The Contractor is required to M/ORT&H During Construction Contractor PMC/KDMC
Health and comply with all the precautions as 105.2
Safety required for the safety of workmen
as per the International Labour
Organization (ILO) convention no.
62 as far as those are applicable
to the Contract.
Provision of The Contractor shall supply all M/ORT&H During Construction Contractor PMC/KDMC
Safety necessary safety appliances such 105.2
accessories/appliances as safety goggles, helmets, safety
to each belts, ear plugs, masks etc. to the
worker worker and staff.
Safety Adequate precautions shall be During Construction Contractor PMC/KDMC
Precautions taken to prevent danger from
electrical equipment. All machines
/ equipment used
Bidder 168KDMC

Issue Documents
shall conform to the relevant
Indian standards (IS) codes
and shall be regularly
inspected by the PMC.
Availability of A readily available first aid unit M/ORT&H During Construction Contractor PMC/KDMC
first aid kit at including an adequate supply 105.2
construction site of sterilized dressing material
and appliances shall be
provided as per the
requirement under the Factory
Act.
Worker’s health All anti-malarial measures as M/ORT&H During Construction Contractor PMC/KDMC
and hygiene prescribed by the PMC shall 105.2
be complied with, including
filling up of burrow pits.
Note: PIA – Project Implementing Authority; KDMC – Kalyan Dombivali Municipal Corporation, PMC – Project Management Consultant, M/ORT&H – Ministry of Road
Transportation and Highways (formerly Ministry of Surface Transport, MOST Specifications for Road and Bridge Works, 3rd Revision, 1997); RAP – Rehabilitation Action Plan;
RIP – Rehabilitation Implementation Plan; R & R – Resettlement and Rehabilitation; CEMP – Community Environmental Management Plan;; D G Sets- Diesel Generator Sets;
ROW - Right of Way; PROW – Proposed Right of Way, O & M – Operation & Maintenance
Bidder 169KDMC
Table - 3 - Environmental Monitoring Plan
Environmental Project Parameters Standard Location Frequency Duration InstitutionalResponsibility

Component Stage Implemen Supervision
tation
Note: KDMC – Kalyan Dombivali Municipal Corporation, PMC – Project Management Consultant; M/ORT&H – Ministry of Road Transportation and Highways (formerly Ministry of
Surface Transport, MOST Specifications for Road and Bridge Works,); RAP – Rehabilitation Action Plan; RIP – Rehabilitation Implementation Plan; CEMP – Community
Environmental Management Plan; CEA – Consolidated Environmental Assessment, ROW – Right of Way; PROW – Proposed Right of Way
Bidder 170KDMC

Volume III LC 51 TD

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Volume III LC 51 TD

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KALYAN DOMBIVLI MUNICIPAL CORPORATION, KALYAN

CONSTRUCTION OF APPROACHES TO PROPOSED

2 Technical Standards & Specifications

Part A General Technical Specifications 6

Part B Amendments / Modifications / Additions 6

1.2 Site Information

1.2.3 General Climatic Conditions

1.2.3.1 The temperature in this region is as under:

a) During summer months, the maximum temperature is 40 C

b) During winter months, the minimum temperature is 12 C

1.2.3.2 The average annual rainfall in the area is above 1500mm.

1.2.4 Seismic Zone

The work is located in Seismic Zone-III as defined in IRC: 6-2014.

2 Technical Standards & Specifications

Ministry of Road Transport and Highways (formerly the Ministry of Surface

Where reference is made in the Contract to specific standards codes to be met by

Part B -Amendments/Modifications/Additions to Existing clauses of General

The Supplementary Technical Specifications shall comprise of various

A particular Clause or a part thereof in “SPECIFICATIONS FOR ROAD AND

The Additional Specifications shall comprise of specifications for particular items

When an Amended/Modified/Added Clause super cedes a Clause or part thereof

In so far as Amended/Modified/Added Clause may come in conflict or be

Amended/Modified/Added Clause shall always prevail.

The following Clauses in the “SPECIFICATIONS FOR ROAD AND BRIDGE

1 1 2 108, 110, 111, 112,120, 200, 201,202, 300, 301, 305,

CLAUSE SP-1 PLANT AND EQUIPMENT FOR AGGREGATES AND

CLAUSE SP-2 FIXING DOWEL BARS IN CONCRETE

CLAUSE SP-3 CURING USING LIQUID MEMBRANE FORMING COMPOUND

CLAUSE SP-4 ADDITIONAL TECHNICAL SPECIFICATIONS FOR ROAD SIGNS

CLAUSE SP-5 ADDITIONAL SPECIFICATIONS FOR TRAFFIC MANAGEMENT

CLAUSE SP-6 SPECIFICATIONS FOR INTER-LOCKING CONCRETE PAVING

CLAUSE SP-7 STREET LIGHTING INSTALLATION

CLAUSE SP-9 GEOTECHNICAL INVESTIGATIONS (DETAILED

CLAUSE SP-10 ADDITIONAL SPECIFICATION FOR PROTECTIVE COATING

CLAUSE SP-11 SPECIFICATION FOR PRECAST CONCRETE SEGMENTAL

CLAUSE SP 12 REINFORCED EARTH WALL

CLAUSE SP 12 STRUCTURAL STEEL WORKS

CLAUSE SP-13 ENVIRONMENTAL MANAGEMENT PLAN

Part A:-The General Technical Specifications shall be the “SPECIFICATIONS FOR

PART B AMENDMENTS/MODIFICATIONS/ADDITIONS TO EXISTING CLAUSES

SECTION 100 GENERAL CLAUSE 102 DEFINITIONS

The Contractor shall make adequate provision, including frequent

Sub-Clause 111.16:- Water Sources and Water Quality

permission of the Engineer in charge and the regulatory authority

Sub-Clause 111.19:- Vibration Control

Spilling of oil and bituminous products during construction and

materials shall be stored in a well-ventilated room, well-guarded

E 120 FIELD LABORATORIES

SECTION 200 SITE CLEARANCES

SECTION 300:- EARTHWORK, EROSION CONTROL AND DRAINAGE

Sub-Clause 301.3.7:-Excavation of road shoulders/verge/medians for widening of

The title of this Clause shall read as under:

"Excavation of road shoulders/verge & medians for widening of

CLAUSE 304 EXCAVATIONS FOR STRUCTURES

Clause 305.2.2.2: - Borrow Materials

Sub-Clause 305.2.2.4:- Compaction Requirements

Compaction Requirements of Embankment and Subgrade