Morth 4 RTH

Ministry of Road Tr
Highways
SP
EC
IFI
CA
TI
ON
S
FO
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RO
AD
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Page 1 of 1427
BR
ID
GE
W
OR
KS
(Fourth
Revisio
n)
Page 2 of 1427
Publish
ed by
the
Indian
Roads
Congres
s on
behalf
of the
Govt. of
India,
Ministr
y of
Road
Transpo
rt &
Highwa
ys
Copies
can be
had
from
the
Secreta
Page 3 of 1427
ry,
Indian
Roads
Congre
ss,
Jamnag
ar
House,
Shahja
han
Road,
New
Delhi-
110 011
NEW
DELHI
2001
Price
Rs.600/
-
Plus
packing
&
postage
charges
Page 4 of 1427
First Published : April, 1973
Reprinted : November, 1975
First Revision : May, 1978
Reprinted : September, 1981
Reprinted : October, 1983
Reprinted : April, 1986
Second Revision : February, 1988
Reprinted : August, 1988
Reprinted : April, 1990
Reprinted : June, 1992
Reprinted : February, 1993
Reprinted : July, 1993
Third Revision : April, 1995
Reprinted : January, 1997 (Incorporates Corrigendum
12 & 15 of p.662)
Reprinted : January, 1998
Reprinted : May, 1999
Reprinted : February, 2000
Reprinted : September, 2000 (Section 700 “Geosy
“Geosynthetics and Reinforced Earth”
Fourth Revision : August, 2001
Reprinted : March, 2002
Reprinted : September, 2002
Reprinted : November, 2002
Reprinted : March, 2003
Reprinted : June, 2003
Reprinted : July, 2003
Reprinted : December, 2003
Page 5 of 1427
(The Rights of Publication and Translation are
reserved)
Printed at Dee Kay Printers, New Delhi - 110 015

(1000 copies)
Page 6 of 1427
PREFACE TO THE FOURTH REVISION
This edition of Specifications for Road &

Bridge Works marks the fourth revision. In the past
few years significant developments have taken place
in the road sector. A large scale highway
modernisation programme has been undertaken
which opens up immense opportunities to introduce
innovative materials and new techniques in highway
construction and maintenance. The major emphasis
is on pavement durability and cost effective
solutions with environmental preservation and road
user safety in focus. In keeping with these needs
Addendum to Third Revision of Specifications was
issued in November, 2000, which included revised
specifications for bituminous work covered under
Sections 500, 900 & 3000 on the basis of indigenous
research results, feed back and international
practices. The fourth revision incorporates the
Addendum and other amendments and changes that
have been effected till date.
The most important additions to the range of
specifications are bituminous cold mixes, modified
binders, crack prevention courses, and sand asphalt
base course. It is hoped that the new specifications
introduced for the first time will find wide
application in practice, and feed back on their
performance will be made available by field
engineers and users of this document for further
improvement in its future editions.
The fourth revision of Specifications for
Road & Bridge Works has been possible with
Page 7 of 1427
concerted efforts of the officers of the Roads Wing,
the consultants and several other individuals who
contributed to this document. I wish to express my
gratitude to them all.
(
S
.
C
.
S
H
A
R
M
A
)
New Delhi Director
General (Road Development) &
August, 2001
Additional Secretary to the Govt. of India
Page 8 of 1427
CONTENTS
SECTION SECTION CLAUSE CLAUSE TITLE
NO. TITLE NO.
100 GENERAL 101 INTRODUCTION
102 DEFINITIONS
103 MATERIALS AND TEST
STANDARDS
104 SIEVE DESIGNATIONS
105 SCOPE OF WORK
106 CONSTRUCTION EQUIP
107 CONTRACT DRAWINGS
108 SITE INFORMATION
109 SETTING OUT
110 PUBLIC UTILITIES
111 PRECAUTIONS FOR
SAFEGUARDING
THE ENVIRONMENT
112 ARRANGEMENT FOR TR
DURING CONSTRUCTIO
113 GENERAL RULES FOR T
MEASUREMENT OF WO
PAYMENT
114 SCOPE OF RATES FOR
DIFFERENT ITEMS OF W
115 METHODOLOGY AND
OF WORK
116 CRUSHED STONE AGGR
117 APPROVAL OF MATERI
118 SUPPLY OF QUARRY SA
119 USE OF SURFACES BY
CONSTRUCTION TRAFF
120 SITE OFFICE FOR ENGI
Page 9 of 1427
OTHER SUPERVISORY S
121 FIELD LABORATORY
122 SITE RESIDENTIAL
ACCOMMODATION FOR
ENGINEER AND OTHER
SUPERVISORY STAFF
123 PROVIDING AND MAIN
WIRELESS COMMUNICA
SYSTEM
124 PROVIDING AND MA
VEHICLES FOR THE EN
125 SUPPLY OF COLOUR
PHOTOGRAPHS AND AL
126 SUPPLY OF VIDEO CAS
200 SITE 201 CLEARING AND GRUBB
CLEARANCE 202 DISMANTLING CULVER
BRIDGES AND OTHER
STRUCTURES/PAVEMEN
Page 10 of 1427
NO. TITLE NO.
300 EARTHWORK 301 EXCAVATION FOR ROA
EROSION AND DRAINS
CONTROL 302 BLASTING OPERATION
AND
DRAINAGE 303 PRESPLITTING ROCK
EXCAVATION SLOPES
304 EXCAVATION FOR STR
305 EMBANKMENT CONSTR
306 SOIL EROSION AND
SEDIMENTATION CONT
307 TURFING WITH SODS
308 SEEDING AND MULCHI
309 SURFACE/SUB-SURFAC
310 PREPARATION AND SU
TREATMENT OF FORMA
311 WORKS TO BE KEPT FR
WATER
312 WATER COURSES AT C
313 CONSTRUCTION OF RO
EMBANKMENT
400 SUB-BASES, 401 GRANULAR SUB-BASE
BASES (NON- 402 LIME TREATED SOIL FO
BITUMINOUS) IMPROVED
AND SUB-GRADE/SUB-BASE
SHOULDERS 403 CEMENT TREATED SOIL
BASE/BASE
404 WATER BOUND MACAD
SUB-BASE/BASE
405 CRUSHED CEMENT CON
Page 11 of 1427
SUB-BASE/BASE
406 WET MIX MACADAM SU
BASE
407 SHOULDERS, ISLANDS
MEDIAN
408 CEMENT CONCRETE KE
KERB WITH CHANNEL
409 FOOTPATHS AND SEPA
410 CRUSHER-RUN MACAD
500 BASES AND 501 GENERAL REQUIREMEN
SURFACE BITUMINOUS PAVEMEN
COURSES ANNEXURE A TO 501
(BITUMINOUS) PROTECTION OF THE
ENVIRONMENT
502 PRIME COAT OVER GRA
BASE
503 TACK COAT
504 BITUMINOUS MACADA
Page 12 of 1427
NO. TITLE NO.
505 BITUMINOUS PENETRA
MACADAM
506 BUILT-UP SPRAY GROU
507 DENSE GRADED BITUM
MACADAM
508 SEMI-DENSE BITUMINO
CONCRETE
509 BITUMINOUS CONCRET
510 SURFACE DRESSING
511 OPEN-GRADED PREMIX
SURFACING
512 CLOSE-GRADED PREMI
SURFACING/ MIXED SE
SURFACING
513 SEAL COAT
514 SUPPLY OF STONE AGG
FOR PAVEMENT COURS
515 MASTIC ASPHALT
516 SLURRY SEAL
517 RECYCLING OF BITUMI
PAVEMENT
518 FOG SPRAY
519 BITUMINOUS COLD MIX
(INCLUDING GRAVEL E
520 SAND ASPHALT BASE C
521 MODIFIED BINDER
Page 13 of 1427
522 CRACK PREVENTION C
600 CONCRETE 601 DRY LEAN CEMENT CO
PAVEMENT SUB-BASE
602 CEMENT CONCRETE PA
603 ROLLED CEMENT CONC
BASE
700 GEOSYNTHETICS 701 GEOSYNTHETICS IN RO
BRIDGE WORKS
702 GEOTEXTILES IN SUB-S
DRAINS
703 GEOSYNTHETICS FOR H
PAVEMENTS
704 PROTECTION WORKS W
GEOSYNTHETICS
Page 14 of 1427
NO. TITLE NO.
800 TRAFFIC SIGNS, 801 TRAFFIC SIGNS
MARKINGS & 802 OVERHEAD SIGNS
OTHER ROAD 803 ROAD MARKINGS
APPURTENANCES 804 HECTOMETRE/KILOME
STONES
805 ROAD DELINEATORS
806 BOUNDARY STONES
807 FENCING
808 TUBULAR STEEL RAILI
809 CONCRETE CRASH BAR
810 METAL BEAM CRASH B
811 ROAD TRAFFIC SIGNAL
900 QUALITY 901 GENERAL
CONTROL 902 CONTROL OF ALIGNME
FOR ROAD AND SURFACE REGULA
WORKS 903 QUALITY CONTROL TE
DURING CONSTRUCTIO
1000 MATERIALS 1001 GENERAL
FOR 1002 SOURCES OF MATERIA
STRUCTURES 1003 BRICKS
1004 STONES
1005 CAST IRON
1006 CEMENT
1007 COARSE AGGREGATES
1008 SAND/FINE AGGREGAT
Page 15 of 1427
1009 STEEL
1010 WATER
1011 TIMBER
1012 CONCRETE ADMIXTUR
1013 REINFORECED CONCRE
1014 STORAGE OF MATERIA
1015 TESTS AND STANDARD
ACCEPTANCE
1100 PILE 1101 DESCRIPTION
FOUNDATION 1102 SUB-SURFACE INVESTI
S
1103 TYPE OF FILES
1104 MATERIALS
1105 TEST PILES
1106 PRECAST CONCRETE PI
Page 16 of 1427
NO. TITLE NO.
1107 CAST-IN-SITU CONCRE
1108 STEEL PILES
1109 TIMBER PILES
1110 DRIVING EQUIPMENT
1111 DRIVING
1112 RAKER (INCLINED) PILE
1113 PILE TESTS
1114 PILE CAP
1115 IMPORTANT CONSIDER
INSPECTION/PRECAUTI
FOR DIFFERENT TYPES
1116 TOLERANCES
ACCEPTANCE
1118 MEASUREMENTS FOR P
1119 RATE
1200 WELL 1201 DESCRIPTION
FOUNDATIONS 1202 GENERAL
1203 SETTING OUT AND
PREPARATIONS FOR SIN
1204 CUTTING EDGE
1205 WELL CURB
1206 WELL STEINING
1207 WELL SINKING
Page 17 of 1427
1208 BOTTOM PLUG
1209 SAND FILLING
1210 TOP PLUG
1211 WELL CAP
1212 TOLERANCES
ACCEPTANCE
1215 RATE
1300 BRICK 1301 DESCRIPTION
MASONRY 1302 MATERIALS
1303 PERSONNEL
1304 CEMENT MORTAR
1305 SOAKING OF BRICKS
1306 JOINTS
Page 18 of 1427
NO. TITLE NO.
1307 LAYING
1308 JOINTING OLD AND NE
1309 CURING
1310 SCAFFOLDING
1311 EQUIPMENT
1312 FINISHING OF SURFACE
1313 ARCHITECTURAL COPI
WING/RETURN/PARAPE
1314 ACCEPTANCE OF WORK
1316 RATE
1400 STONE 1401 DESCRIPTION
MASONRY 1402 MATERIALS
1403 PERSONNEL
1404 TYPE OF MASONRY
1405 CONSTRUCTION OPERA
1406 ARCHITECTURAL COPI
WING/RETURN/PARAPE
ACCEPTANCE
1409 RATE
1500 FORMWORK 1501 DESCRIPTION
1502 MATERIALS
Page 19 of 1427
1503 DESIGN OF FORMWORK
1504 WORKMANSHIP
1505 FORMED SURFACE AND
1506 PRECAUTIONS
1507 PREPARATION OF FORM
BEFORE CONCRETING
1508 REMOVAL OF FORMWO
1509 RE-USE OF FORMWORK
1510 SPECIALISED FORMWO
OF ACCEPTANCE
1513 RATE
Page 20 of 1427
NO. TITLE NO.
1600 STEEL 1601 DESCRIPTION
REINFOR-
CEMENT 1602 GENERAL
UNTENSIONED 1603 PROTECTION OF
REINFORCEMENT
1604 BENDING OF REINFORC
1605 PLACING OF REINFORC
1606 BAR SPLICES
1607 TESTING AND ACCEPTA
1609 RATE
1700 STRUCTURAL 1701 DESCRIPTION
CONCRETE 1702 MATERIALS
1703 GRADES OF CONCRETE
1704 PROPORTIONING OF CO
1705 ADMIXTURES
1706 SIZE OF COARSE AGGR
1707 EQUIPMENT
1708 MIXING CONCRETE
1709 TRANSPORT, PLACING
COMPACTION OF CONC
1710 CONSTRUCTION JOINTS
1711 CONCRETING UNDER W
1712 ADVERSE WEATHER CO
1713 PROTECTION AND CUR
Page 21 of 1427
1714 FINISHING
1715 TOLERANCES
ACCEPTANCE
1718 RATE
1800 PRESTRESSING 1801 DESCRIPTION
1802 MATERIALS
1803 TESTING OF PRESTRESS
STEEL AND ANCHORAG
1804 WORKMANSHIP
1805 SUPERVISION
1806 TENSIONING EQUIPMEN
1807 POST-TENSIONING
Page 22 of 1427
NO. TITLE NO.
1808 GROUTING OF PRESTRE
TENDONS
1809 PRE-TENSIONING
1810 SAFETY PRECAUTIONS
DURING TENSIONING
1811 TRANSPORTATION AND
STORAGE OF UNITS
1812 TOLERANCES
ACCEPTANCE
1815 RATE
1900 STRUCTURAL 1901 DESCRIPTION
STEEL 1902 GENERAL
1903 MATERIALS
1904 FABRICATION
1905 ERECTION
1906 PAINTING
ACCEPTANCE
1909 RATE
2000 BEARINGS 2001 DESCRIPTION
2002 GENERAL
Page 23 of 1427
2003 STEEL BEARINGS
2004 SPECIAL BEARINGS
2005 ELASTOMERIC BEARIN
2006 POT BEARINGS
2007 INSPECTION AND TEST
ACCEPTANCE
2010 RATE
2100 OPEN 2101 DESCRIPTION
FOUNDATIONS 2102 MATERIALS
2103 GENERAL
2104 WORKMANSHIP
ACCEPTANCE
Page 24 of 1427
NO. TITLE NO.
2106 TOLERANCES
2108 RATE
2200 SUB- 2201 DESCRIPTION
STRUCTURE
2202 MATERIALS
2203 GENERAL
2204 PIERS AND ABUTMENT
2205 PIER CAP AND ABUTME
2206 DIRT/BALLAST WALL, R
WALL & WING WALL
ACCEPTANCE
2208 TOLERANCES IN CONC
ELEMENTS
2210 RATE
2300 CONCRETE 2301 DESCRIPTION
SUPER- 2302 MATERIALS
STRUCTURE 2303 GENERAL
2304 REINFORCED CONCRET
CONSTRUCTION
2305 PRESTRESSED CONCRE
CONSTRUCTION
2306 TOLERANCES
Page 25 of 1427
ACCEPTANCE
2309 RATE
2400 SURFACE AND 2401 GENERAL
SUB-SURFACE 2402 PRELIMINARY INVESTI
GEOTECHNICAL 2403 DETAILED EXPLORATIO
EXPLORATION 2404 EXPLORATION FOR BR
FOUNDATIONS RESTIN
ROCK
2405 BORING
2406 RECORDS OF BORING A
PITS
2407 METHODS OF SAMPLIN
2408 PROCEDURE TOR TAKI
SAMPLES
Page 26 of 1427
NO. TITLE NO.
2409 PROTECTION, HANDLIN
LABELLING OF SAMPLE
2410 TESTS FOR EXPLORATI
SHALLOW FOUNDATIO
BRIDGES
2411 TESTS FOR EXPLORATI
DEEP FOUNDATIONS O
2412 TESTING OF MATERIAL
GUIDE BUND AND HIGH
EMBANKMENT AND ITS
FOUNDATIONS
2414 RATE
2500 RIVER 2501 DESCRIPTION
TRAINING
WORK AND 2502 GUIDE BUND
PROTECTION 2503 APRON
WORK 2504 PITCHING/REVETMENT
SLOPES
2505 RUBBLE STONE/CEMEN
CONCRETE BLOCK FLO
OVER CEMENT CONCRE
BEDDING
2506 DRY RUBBLE FLOORIN
2507 CURTAIN WALL AND F
APRON
ACCEPTANCE
Page 27 of 1427
2510 RATE
2600 EXPANSION 2601 DESCRIPTION
JOINTS 2602 GENERAL
2603 REQUIREMENTS
2604 STEEL PLATE SLIDING
EXPANSTION JOINTS
2605 FILLER JOINTS
2606 ELASTOMERIC SLAB SE
EXPANSION JOINT
2607 STRIP SEAL EXPANSION
ACCEPTANCE
2610 RATE
Page 28 of 1427
NO. TITLE NO.
2700 WEARING 2701 DESCRIPTION
COAT AND 2702 WEARING COAT
APPURT 2703 RAILINGS
ENANCES
2704 APPROACH SLAB
2705 DRAINAGE SPOUTS
2706 WEEP HOLE
ACCEPTANCE
2709 RATE
2800 REPAIROF 2801 DESCRIPTION
STRUCTURES 2802 GENERAL
2803 SEALING OF CRACKS B
INJECTION OF EPOXY R
2804 EPOXY MORTAR FOR
REPLACEMENT
OF SPALLED CONCRET
2805 EPOXY BONDING OF NE
CONCRETE TO OLD CO
2806 CEMENT GROUTING
2807 GUNITING/SHOTCRETE
2808 REPLACEMENT/RECTIF
OF BEARINGS
2809 DISMANTLING OF CON
Page 29 of 1427
WEARING COAT
2810 EXTERNAL PRESTRESS
ACCEPTANCE
2813 RATE
2900 PIPE 2901 SCOPE
CULVERTS 2902 MATERIALS
2903 EXCAVATION FOR PIPE
2904 BEDDING FOR PIPE
2905 LAYING OF PIPE
2906 JOINTING
2907 BACKFILLING
2908 HEADWALLS AND OTH
ANCILLARY WORKS
Page 30 of 1427
NO. TITLE NO.
2909 OPENING TO TRAFFIC
2911 RATE
3000 MAINTENANC 3001 GENERAL
E
OF ROAD 3002 RESTORATION OF RAIN
3003 MAINTENANCE OF EAR
SHOULDERS
3004 BITUMINOUS WORK IN
CONNECTION WITH
MAINTENANCE AND RE
3005 MAINTENANCE OF CEM
CONCRETE ROAD
3100 REINFORCED 3101 SCOPE
EARTH 3102 REINFORCING ELEMEN
3103 EARTH FILL
3104 FACIA MATERIAL
3105 CONSTRUCTION DETAI
3107 RATE
Page 31 of 1427
SECTION NO. SECTION CLAUSE TITLE
TITLE
APPENDICES
APPENDIX 1. LIST OF I.R.C. PUBLICATIONS RE
TO IN THE SPECIFICATIONS, COD
STANDARDS
APPENDIX 2. LIST OF INDIAN AND FOREIGN
STANDARDS REFERRED TO IN T
SPECIFICATIONS
APPENDIX 3. METHOD OF SIEVING FOR WET
DETERMINE THE DEGREE OF
PULVERISATION
APPENDIX 4. GUIDELINES ON SELECTION OF
GRADE OF BITUMEN
APPENDIX 5. ANTI-STRIPPING AGENTS USED
BITUMINOUS MATERIALS AND M
APPENDIX 1000-1 DRAFT DOCUMENT ON ISC 9077
OF PRACTICE FOR CORROSION
PROTECTION OF STEEL REINFOR
IN RB AND RCC CONSTRUCTION
(REVISED)
APPENDIX 1200/I-1 HISTORY OF SINKING OF WELL
1200/I-2 PLAN OF WELL NOS.
1200/II TILT AND SHIFT IN WELL NOS.
APPENDIX 1500/I INFORMATION TO BE SUPPLIED
MANUFACTURERS OF PROPRIET
SYSTEMS
APPENDIX 1700/I SPECIFICATION FOR CONSTRUC
JOINTS
Page 32 of 1427
1700/II PERMEABILITY TEST
APPENDIX 1800/I TESTS ON SHEATHING DUCTS
1800/II PRESTRESSING REPORT
1800/IIISPECIFICATIONS FOR GROUTING
TENSIONED CABLES IN PRESTR
CONCRETE
1800/IV GROUTING RECORD
Page 33 of 1427
General
Section 100
General
Page 34 of 1427
101. INTRODUCTION
These Specifications shall apply to all such

road and bridge works as are required to be executed
under the Contract or otherwise directed by the
Engineer-in-Charge (hereinafter referred to as the
Engineer). In every case, the work shall be carried
out to the satisfaction of the Engineer and conform
to the location, lines, dimensions, grades and cross-
sections shown on the drawings or as indicated by
the Engineer. The quality of materials, processing of
materials as may be needed at the site, salient
features of the construction work and quality of
finished work shall comply with the requirements set
forth in succeeding sections. Where the drawings
and Specifications describe a portion of the work in
only general terms, and not in complete detail, it
shall be understood that only the best general
practice is to prevail, materials and workmanship of
the best quality are to be employed and instructions
of die Engineer are to be fully complied with.
A list of Indian Roads Congress
Specifications and Recommended Codes of Practice
which have been made use of in the preparation of
these Specifications is given at Appendix-1. The
latest edition of all Specifications/Standards till 30
(thirty) days before the final date of submission of
the tender, shall be adopted.
102. DEFINITIONS
The words like Contract, Contractor,
Page 35 of 1427
Engineer (synonymous with Engineer-in-charge),
Drawings, Employer, Government, Works and Work
Site used in these Specifications shall be considered
to have the meaning as understood from the
definitions of these terms given in the General
Conditions of Contract.
The following abbreviations shall have the

meaning as set forth below:
AASHTO : American Association of Slate

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

road referred to in these Specifications are shown in
the cross-sections in Figs. 100-1 and 100-2.
Page 36 of 1427
Page 37 of 1427
Page 38 of 1427
Page 39 of 1427
Treated shoulders shown in the cross-section
shall be of two types:-
(i) “Hard” shoulders which have select
gravel/moorum, any other compacted
granular layer or bricks.
(ii) “Paved” shoulders which have a
bituminous surfacing over granular layers.
103. MATERIALS AND TEST STANDARDS
The relevant standards for materials, as well

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

Specifications correspond to those specified by
Bureau of Indian Standards in IS: 460. Table 100-1
gives the list of the commonly used IS sieves.
TABLE 100-1. DESIGNATION OF TEST

SIEVES
IS Designation conforming to IS: 460
(in mm)
*125
106
* 90
Page 40 of 1427
75
* 63
53
* 45
37.5
* 31.5
26.5
* 22.4
19.0
* 16.0
13.2
* 11.2
9.50
* 8.00
6.70
* 5.60
4.75
* 4.00
3.35
* 2.80
2.36
* 2.00
1.70
* 1.40
1.18
Page 41 of 1427
Note: 1. ‘*’ are the principal sizes stated in ISO-
565 and are preferred.
2. Sieve sizes given in BS.410 & ASTM -
E 11 are same as in IS:460
3. Only sieves with square openings shall
be used.
105. SCOPE OP WORK
105.1. The work to be carried out under the

Contract shall consist of the various items as
generally described in the Tender Documents as
well as in the Bill of Quantities furnished in the
Tender Documents.
105.2. The works to be performed shall also

include all general works preparatory to the
construction of roads, bridges, canal crossings,
drainage and all other related works. The works shall
include work of any kind necessary for the due and
satisfactory construction, completion and
maintenance of the works to the intent and meaning
of the drawings and these Specifications and further
drawing and orders that may be issued by the
Engineer from time to time. The scope of work shall
include compliance by the Contractor with all
General Conditions of Contract, whether specifically
mentioned or not in the various clauses of these
Specifications, all materials, apparatus, plant,
equipment, tools, fuel, water, strutting, timbering,
Page 42 of 1427
transport, offices, stores, workshop, staff, labour and
the provision of proper and sufficient protective
works, diversions, temporary fencing and lighting. It
shall also include: safety of workers, first-aid
equipment, suitable accommodation for the staff and
workmen with adequate sanitary arrangements, the
effecting and maintenance of all insurances, the
payment of all wages, salaries, fees, royalties, duties
or other charges arising out of the erection of works
and the regular clearance of rubbish, reinstatement
and clearing-up of the site as may be required on
completion of works, safety of the public and
protection of the works and adjoining land.
105.3. The Contractor shall ensure that all

actions are taken to build in quality assurance in the
planning and execution of works. The quality
assurance shall cover all stages of work such as
setting out, selection of materials, selection of
construction methods, selection of equipment and
plant, deployment of personnel and supervisory staff,
quality control testing etc. The work of building
in quality assurance shall be deemed to be covered
in the scope of the work.
105.4. The Contractor shall furnish, at least

15 days in advance, his programme of
commencement of item of work, the method of
working he intends to adopt for various items of
work such as site clearance, construction for
embankment, sub-base, base, surfacing, culverts,
bridges, retaining walls, well-sinking, cast-in-situ
Page 43 of 1427
piling, construction of cast-in-situ prestressed
concrete simply supported girders, cantilever
construction of prestressed concrete superstructure,
and such other items for which the
Page 44 of 1427
Engineer demands the submission of the method of
working. He shall provide information regarding
the details of the method of working and equipment
he proposes to employ and satisfy the Engineer
about the adequacy and safety of the same. The sole
responsibility for the safety and adequacy of the
methods adopted by the Contractor will, however,
rest on the Contractor, irrespective of .any approval
given by the Engineer.
106. CONSTRUCTION EQUIPMENT
In addition to the general conditions

indicated in the Contract Documents, the following
conditions regarding use of equipment in works shall
be satisfied:
(a) The Contractor shall be required lo give a
trial run of the equipment for establishing
their capability to achieve the laid down
Specifications and tolerances to the
satisfaction of the Engineer before
commencement of the work;
(b) All equipment provided shall be of proven
efficiency and shall be operated and
maintained at all limes in a manner
acceptable to the Engineer;
(c) All the plant/equipment to be deployed on
the works shall be got approved from the
Engineer for ensuring their fitness and
efficiency before commencement of work;
(d) Any material or equipment not meeting the
approval of the Engineer shall be removed
Page 45 of 1427
from the site forthwith;
(e) No equipment will be removed from site
without permission of the Engineer; and
(f) The Contractor shall also make available the
equipment for site quality control work as
directed by the Engineer.
107. CONTRACT DRAWINGS
107.1. The Contract Drawings provided for

tendering purposes shall be as contained in the
Tender Documents and shall be used as a reference
only. The Contractor should visualise the nature and
type of work contemplated and to ensure that the
rates and prices quoted by him in the Bill of
Quantities have due consideration of the qualitative
and quantitative variations, as may be found at the
site and complexities of work involved during actual
execution/construction.
107.2. The tendered rates/prices for the work

shall be deemed to include the cost of preparation,
supply and delivery of all necessary drawings, prints,
tracings and negatives which the Contractor is
required to provide in accordance with the Contract.
107.3. Two copies of drawings, on the basis

of which actual execution of the work is to proceed,
shall be furnished free of cost to the Contractor by
the Engineer progressively according to the work
programme submitted by the Contractor and
accepted by the Engineer. Drawings for any
Page 46 of 1427
particular activity shall be issued to the Contractor at
least 30 days in advance of the scheduled date of the
start of the activity.
107.4. Examination and /or approval by the

Engineer of any drawings or other documents
submitted by the Contractor shall not relieve the
Contractor of his responsibilities or liabilities under
the Contract.
Page 47 of 1427
108. SITE INFORMATION
108.1. The information about the site of

work and site conditions in the Tender Documents is
given in good faith for guidance only but the
Contractor shall satisfy himself regarding all aspects
of site conditions.
108.2. The location of the works and the

general site particulars are as generally shown on the
Site plan/Index plan enclosed with the Tender
Documents.
108.3. Whereas the right-of-way to the

bridge sites/road works shall be provided to the
Contractor by the Engineer, the Contractor shall
have to make his own arrangement for the land
required by him for site offices, labour camps,
stores, etc.
108.4. The quarry charts enclosed with the

Tender Documents indicate the location of quarries
and other sources from which naturally occurring
materials are available, for guidance of the
Contractor. The leads indicated in the said charts are
only approximate. It is assumed that the Contractor
has inspected the quarries, borrow-areas etc., before
quoting his rates for the work to assess the
availability of construction materials in required
quantity and quality.
109. SETTING OUT
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109.1. The Contractor shall establish
working Bench Marks tied with the Reference
Bench Mark in the area soon after taking possession
of the site. The Reference Bench Mark for the area
shall be as indicated in the Contract Documents and
the values of the same shall be obtained by the
Contractor from the Engineer. The working Bench
Marks shall be at the rate of four per km and also at
or near all drainage structures, over-bridges and
underpasses. The working Bench Marks/levels
should be got approved from the Engineer. Checks
must be made on these Bench Marks once every
month and adjustments, if any, got agreed with the
Engineer and recorded. An up-to-date record of all
Bench Marks including approved adjustments, if
any, shall be maintained by the Contractor and also a
copy supplied to the Engineer for his record.
109.2. The lines and levels of formation,

side slopes, drainage works, carriageways and
shoulders shall be carefully set out and frequently
checked, care being taken to ensure that correct
gradients and cross-sections are obtained
everywhere.
109.3. In order to facilitate the setting out of

the works, the centre line of the carriageway or
highway must be accurately established by the
Contractor and approved by the Engineer. It must
then be accurately referenced in a manner
satisfactory to the Engineer, every 50 m intervals in
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plain and rolling terrains and 20 m intervals in hilly
terrain and in all curve points as directed by the
Engineer, with marker pegs and chainage boards set
in or near the fence line, and a schedule of reference
dimensions shall be prepared and supplied by the
Contractor to the Engineer. These markers shall be
maintained until the works reach finished
formation level and are accepted by the Engineer.
109.4. On construction reaching the

formation level stage, the centre line shall again be
set out by the Contractor and when approved by the
Engineer, shall be accurately referenced in a
manner satisfactory to the Engineer by marker pegs
set at the
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outer limits of the formation.
109.5. No reference peg or marker shall be

moved or withdrawn without the approval of the
Engineer and no earthwork or structural work shall
be commenced until the centre line has been
referenced.
109.6. The Contractor will Be the sole

responsible party for safe-guarding all survey
monuments, bench marks, beacons, etc. The
Engineer will provide the Contractor with the data
necessary for setting out of the centre line. All
dimensions and levels shown on the drawings or
mentioned in documents forming part of or issued
under the Contract shall be verified by the
Contractor on the site and he shall immediately
inform the Engineer of any apparent errors or
discrepancies in such dimensions or levels. The
Contractor shall in connection with the staking out of
the centre line, survey the terrain along the road and
shall submit to the Engineer for his approval, a
profile along the road centre line and cross-sections
at intervals as required by the Engineer.
109.7. After obtaining approval of the

Engineer, work on earthwork can commence and the
profile and cross-sections shall form the basis for
measurements and payment. The Contractor shall be
responsible for ensuring that all the basic
traverse points are in place at the
commencement of the contract and if any are
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missing, or appear to have been disturbed, the
Contractor shall make arrangements to re-establish
these points. A “Survey File” containing the
necessary data will be made available for this
purpose. If in the opinion of the Engineer, design
modifications of the centre line or grade are
advisable, the Engineer will issue detailed
instructions to the Contractor and the Contractor
shall perform the modifications in the field, as
required, and modify the ground levels on the cross-
sections accordingly as many times as required.
There will be no separate payment for any survey
work performed by the Contractor. The cost of these
services shall, be considered as being included in
the cost of the items of work in the Bill of
Quantities.
109.8. The work of setting out shall be

deemed to be a part of general works preparatory
to the execution of work and no separate payment
shall be made for the same.
109.9. Precision automatic levels, having a

standard deviation of ±2 mm per km, and fitted
with micrometer attachment shall be used for all
double run levelling work. Setting out of the road
alignment and measurement of angles shall be done
by using theodolite with traversing target, having an
accuracy of one second. Measurement of distances
shall be done preferably using precision instruments
like Distomat.
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110. PUBLIC UTILITIES
110.1. Drawings scheduling the affected

services like water pipes, sewers, oil pipelines,
cables, gas ducts etc. owned by various authorities
including Public Undertakings and Local Authorities
included in the Contract Documents shall be verified
by the Contractor for the accuracy of the information
prior to the commencement of any work.
110.2. Notwithstanding the fact that the

information on affected services may not be
exhaustive, the final position of these services
within the works shall be supposed to
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have been indicated based on the information
furnished by different bodies and to the extent the
bodies are familiar with the final proposals. The
intermediate stages of the works are, however,
unknown at the design stage, these being dictated by
the Contractor’s methods of working. Accordingly,
the Contractor’s programme must take into account
the period of notice and duration of diversionary
works of each body as given on the Drawings and
the Contractor must also allow for any effect of these
services and alterations upon the Works and for
arranging regular meetings with the various bodies at
the commencement of the Contract and throughout
the period of the Works in order to maintain the
required co-ordination. During .the period of the
Works, the Contractor shall have no objection if the
public utility bodies vary their decisions in the
execution of their proposals in terms of programme
and construction, provided that, in the opinion of
the Engineer, the Contractor has received reasonable
notice thereof before the relevant alterations are put
in hand.
110.3. No clearance or alterations to the

utility shall be carried out unless specially ordered
by the Engineer.
110.4. Any services affected by the Works

must be temporarily supported by the Contractor
who must also take all measures reasonably required
by the various bodies to protect their services and
property during the progress of the Works.
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110.5. The Contractor may be required to
carry out certain works for and on behalf of the
various bodies and he shall also provide, with the
prior approval of the Engineer, such assistance to the
various bodies as may be authorised by the Engineer.
110.6. The work of temporarily supporting

and protecting the public utility services during
execution of the Works shall be deemed to be part
of the Contract and no extra payment shall be made
for the same.
110.7. The Contractor may be required to

carry out the removal or shifting of certain
services/utilities on specific orders from the
Engineer for which payment shall be made to him.
Such works shall be taken up by the Contractor
only after obtaining clearance from the Engineer
and ensuring adequate safety measures.
111. PRECAUTIONS FOR SAFEGUARDING

THE ENVIRONMENT
111.1. General
The Contractor shall take all precautions for

safeguarding the environment during the course of
the construction of the works. He shall abide by all
laws, rules and regulations in force governing
pollution and environmental protection that are
applicable in the area where the works are situated.
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111.2. Borrowpits for Embankment
Construction
Borrowpits shall not be dug in the right-of-

way of the road. The stipulations in Clause 305.2.2.
shall govern.
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111.3. Quarry Operations
The Contractor shall obtain materials from

quarries only after the consent of the Forest
Department or other concerned authorities is
obtained. The quarry operations shall be undertaken
within the purview of the rules and regulations in
force.
111.4. Control of Soil Erosion,

Sedimentation and Water Pollution
The Contractor shall carry out the works in

such a manner that soil erosion is fully controlled,
and sedimentation and pollution of natural water
courses, ponds, tanks and reservoirs is avoided. The
stipulations in Clause 306 shall govern.
111.5. Pollution from Hot-Mix Plants and

Batching Plants
Bituminous hot-mix plants and concrete

batching plants shall be located sufficiently away
from habitation, agricultural operations or industrial
establishments. The Contractor shall take every
precaution to reduce the levels of noise, vibration,
dust and emissions from his plant and shall be fully
responsible for any claims for damages caused to the
owners of property, fields and residences in the
vicinity.
111.6. Substances Hazardous to Health
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The Contractor shall not use or generate any
materials in the works which are hazardous to the
health of persons, animals or vegetation. Where it is
necessary to use some substances which can cause
injury to the health of workers, the Contractor shall
provide protective clothing or appliances to his
workers.
111.7. Use of Nuclear Gauges
Nuclear gauges shall be used only where

permitted by the Engineer. The Contractor shall
provide the Engineer with a copy of the regulations
governing the safe use of nuclear gauges he intends
to employ and shall abide by such regulations.
111.8. The Contractor must take all

reasonable steps to minimise dust nuisance during
the construction of the works.
111.9. All existing highways and roads

used by vehicle of the Contractor or any of his sub-
contractors or suppliers of materials or plant, and
similarly any new roads which are part of the works
and which are being used by traffic, shall be kept
clean and clear of all dust/mud or other extraneous
materials dropped by the said vehicles or their tyres.
Similarly, all dust/mud or other extraneous materials
from the works spreading on these highways shall be
immediately cleared by the Contractor.
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111.10. Clearance shall be effected
immediately by manual sweeping and removal of
debris, or, if so directed by the Engineer, by
mechanical sweeping and clearing equipment, and
all dust, mud and other debris shall be removed
entirely from the road surface. Additionally, if so
directed by the Engineer, the road surface shall be
hosed or watered using suitable equipment.
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111.11. Any structural damage caused to
the existing roads by the Contractor’s construction
equipment shall be made good without any extra
cost.
111.12. Compliance with the foregoing will

not relieve the Contractor of any responsibility for
complying with the requirements of any Highway
Authority in respect of the roads used by him.
112. ARRANGEMENT FOR TRAFFIC

DURING CONSTRUCTION
112.1. General
The Contractor shall at all limes carry out

work on the highway in a manner creating least
interference to the flow of traffic while consistent
with the satisfactory execution of the same. For all
works involving improvements to the existing
highway, the Contractor shall, in accordance with
the directives of the Engineer, provide and maintain,
during execution of the work, a passage for traffic
either along a part of the existing carriageway under
improvement, or along a temporary diversion
constructed close to the highway. The Contractor
shall take prior approval of the Engineer regarding
traffic arrangements during construction.
112.2. Passage of Traffic along a part of

the Existing Carriageway under
Improvement
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For widening/strengthening existing
carriageway where part width of the existing
carriageway is proposed to be used for passage of
traffic, treated shoulders shall be provided on the
side on which work is not in progress. The treatment
to the shoulder shall consist of providing atleast ISO
mm thick granular base course covered with
bituminous surface dressing in a width of atleast 1.5
m and the surface shall be maintained throughout the
period during which traffic uses the same to the
satisfaction of the Engineer. The continuous length
in which such work shall be carried out, would be
limited normally to 500 m at a place. However,
where work is allowed by the Engineer in longer
stretches passing places atleast 20 m long with
additional paved width of 2.5 m shall be provided at
every 0.5 km interval.
In case of widening existing two-lane to four-
lane, the additional two lanes would be constructed
first and the traffic diverted to it and only thereafter
the required treatment to the existing carriageway
would be carried out. However, in case where on the
request of the Contractor, work on existing two-lane
carriageway is allowed by the Engineer with traffic
using part of the existing carriageway, stipulations as
in para above shall apply.
After obtaining permission of the Engineer,
the treated shoulder shall be dismantled, the debris
disposed of and the area cleared as per the direction
of the Engineer.
112.3. Passage of Traffic along a
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Temporary Diversion
In stretches where it is not possible to pass

the traffic on part width of the carriageway, a
temporary diversion shall be constructed with 7 m
carriageway and 2.5 m earthen shoulders on each
side (total width of roadway 12 m) with the
following provision for road crust in the 7 m width:
(i) 200 mm (compacted) granular
subbase;
(ii) 225 mm (compacted) granular base
course; and
(iii) Premix carpet with Seal Coal/Mix
Seal Surfacing.
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The alignment and longitudinal section of
diversion including junctions and temporary cross
drainage provision shall be as approved by the
Engineer.
112.4. Traffic Safety and Control
The Contractor shall take all necessary

measures for the safety of traffic during construction
and provide, erect and maintain such barricades,
including signs, markings, flags, lights and flagmen
as may be required by the Engineer for the
information and protection of. traffic approaching or
passing through the section of the highway under
improvement. Before taking up any construction, an
agreed phased programme for the diversion of traffic
on the highway shall be drawn up in consultation
with the Engineer.
The barricades erected on either side of the
carriageway/portion .of the carriageway closed to
traffic, shall be of strong design to resist violation,
and painted with alternate black and white stripes.
Red lanterns or warning lights of similar type shall
be mounted on the barricades at night and kept lit
throughout from sunset to sunrise.
At the points where traffic is to deviate from
its normal path (whether on temporary diversion or
part width of the carriageway) the channel for traffic
shall be clearly marked with the aid of pavement
markings, painted drums or a similar device to the
directions of the Engineer. At night, the passage
shall be delineated with lanterns or other suitable
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light source.
One-way traffic operation shall be
established whenever the traffic is to be passed over
part of the carriageway inadequate for two-lane
traffic. This shall be done with the help of temporary
traffic signals or flagmen kept positioned on
opposite sides during all hours. For regulation of
traffic, the flagmen shall be equipped with red and
green flags and lanterns/lights.
On both sides, suitable regulatory/warning
signs as approved by the Engineer shall be installed
for the guidance of road users. On each approach, at
least two signs shall be put up, one close to the point
where transition of carriageway begins and the other
120m away. The signs shall be of approved design
and of reflectory type, if so directed by the Engineer.
112.5. Maintenance of Diversions and

Traffic Control Devices
Signs, lights, barriers and other traffic control

devices, as well as the riding surface of diversions
shall be maintained in a satisfactory condition till
such lime they are required as directed by the
Engineer. The temporary travelled way shall be kept
free of dust by frequent applications of water, if
necessary.
112.6. Measurements for Payment and

Rate
All arrangements for traffic during
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construction including provision of temporary cross
drainage structures, if required, and treated shoulder
as described in Clause 112.2 including their
maintenance, dismantling and clearing debris, where
necessary, shall be considered as incidental to the
works and shall be the Contractor’s responsibility.
The construction of temporary diversion
including temporary cross drainage structures as
described in Clause 112.3, shall be measured in
linear metre and the unit contract rate shall be
inclusive of full compensation for construction
(including supply of material, labour, tools etc.),
maintenance, final dismantling, and disposal.
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113. GENERAL RULES FOR THE
MEASUREMENT
OF WORKS FOR PAYMENT
113.1. General
All measurements shall be made in the metric

system. Different items of work shall be measured in
accordance with the procedures set forth in the
relevant sections read in conjunction with the
General Conditions of Contract. The same shall not,
however, apply in the case of lumpsum contracts.
All measurements and computations, unless
otherwise indicated, shall be carried nearest to the
following limits:
(i) length and breadth
10 mm
(ii) height, depth or thickness of
earthwork, subgrade, sub-bases,
bases, surfacing and structural
members 5 mm
(iii) area
0.01 sq. m.
(iv) cubic contents
0.01 cu. m.
In recording dimensions of work, the

sequence of length, width and height or depth or
thickness shall be followed.
113.2. Measurement of Lead for

Materials
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Where lead is specified in the Contract for
construction-materials, the same shall be measured
as described hereunder:
Lead shall be measured over the shortest
practicable route and r«n the one actually taken and
the decision of the Engineer in this regard shall be
taken as final. Distances upto and including 100 m
shall be measured in units of 50 m, exceeding 100 m
but not exceeding 1 km in units of 100 m and
exceeding 1 km in units of 500 m, the half and
greater than half of the unit shall be reckoned as one
and less than half of the unit ignored. In this regard,
the source of the material shall be divided to suitable
blocks and for each block, the distance from the
centre of the block to the centre of placing pertaining
to that block shall be taken as the lead distance.
113.3. Measurement of Pavement

Thickness for Payment on Volume Basis
The finished thickness of sub-base, base and

bituminous courses to be paid on volume basis shall
be computed in the following manner:
Levels shall be taken before and after
construction, at grid of points 10 m centre to centre
longitudinally in straight reaches but 5 m at curves.
Normally, on two-lane roads, the levels shall be
taken at four positions transversely, at 0.75. and 2.75
m from either edge of the carriageway; and on single
lane roads, these shall be taken at two positions
transversely, being at 1.25 m from either edge of the
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carriageway. For multi-lane roads, levels shall be
taken at two positions transversely for each lane at
locations specified by the Engineer.
Suitable references for the transverse grid
lines should be left in the form of embedded bricks
on either ends or by other means so that it is possible
to locate the grid points for level measurements after
each successive course is laid.
For pavement courses laid only over
widening portions, atleast one line of levels shall be
taken on each Scrip of widening., or more depending
on the width of widening as
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decided by the Engineer.
Notwithstanding the above, the
measurements may be taken at closer intervals also,
if so desired by the Engineer, the need for which
may arise particularly in the case of estimation of the
volume of the material for profile corrective course
(levelling course). The average thickness of the
pavement course in any area shall be the arithmetic
mean of the difference of levels before and after
construction at all the grid points falling in that area,
provided that the thickness of finished work shall be
limited to those shown on die drawings or approved
by the Engineer in writing.
As supplement to level measurements, the
Engineer shall have the option to take cotes/make
holes to check the depth of construction. The holes
made and the portions cut for taking cores shall be
made good by the Contractor by laying fresh
mix/material including compacting as required at no
extra cost immediately after the measurements are
recorded.
113.4. Checking of Pavement Thickness

for Payment on Area Basis
Where payment for any bituminous course in

Section 500 is allowed to be made on area basis, the
Engineer may have its thickness checked with the
help of a suitable penetration gauge at regular
intervals or other means as he may decide.
113.5. Measurement of Bituminous
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Courses for Payment on Weight Basis
Plant-mixed bituminous materials for

pavement courses where designated to be paid on
weight basis shall be weighed on accurate scales
approved by the Engineer. Approved scales shall
mean scales that are of size, capacity, kind and type
suitable for the weighing to be done, and these shall
be properly and adequately installed and maintained.
Prior to the use of the scales and as frequently
thereafter as the Engineer may deem necessary to
ensure accuracy, the scales shall be checked and
approved by the Engineer, or the Engineer may
direct the Contractor to have the scales checked by
other competent agency at the cost of the Contractor.
Location of the scales shall be as designated
by the Engineer. Trucks used for hauling the
material to be weighed shall be weighed empty daily
at such times as the Engineer directs, and each truck
shall bear a plainly legible identification mark.
For materials specified to be measured by
weight, the Engineer will have the option to make
measurements of the finished work by volume in
accordance with Clause 113.3 and such volumes
shall be converted into weight for payment purposes.
The factor for conversion from volume measurement
to weight measurement shall be computed from
representative density of the compacted material at
site determined at locations approved by the
Engineer.
114. SCOPE OF RATES FOR
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DIFFERENT ITEMS OF WORK
114.1. For item rate contracts, the contract

unit rates for different items of work shall be
payment in full for completing the work to the
requirements of the Specifications including full
compensation for all the operations detailed in the
relevant sections of these Specifications under
“Rates”. In the absence of any directions to the
contrary, the rates are to be considered as the full
inclusive rate for finished work covering all labour,
materials, wastage, temporary work, plant,
equipment, over-head charges and profit as well as
the general liabilities, obligations, insurance and
risks arising out of General Conditions of Contract.
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114.2. The item rates quoted by the
Contractor shall, unless otherwise specified, also
include compliance with/supply of the following :
(i) General works such u setting out,
clearance of site before setting out and
clearance of works after completion;
(ii) A detailed programme for the
construction and completion of the
work(using CPM/ PERT techniques)
giving, in addition to construction
activities, detailed network activities for
the submission and approval of materials,
procurement of critical materials and
equipment, fabrication of special
products/equipment and their installation
and testing, and for all activities of the
Employer that are likely to affect the
progress of work etc, including updating
of all such activities on the basis of the
decisions taken at the periodic site review
meetings or as directed by the Engineer;
(iii) Samples of various materials proposed to
be used on the Work for conducting tests
thereon as required as per the provisions
of the Contract;
(iv) Design of mixes as per the relevant
Clauses of the Specifications giving
proportions of ingredients, sources of
aggregates and binder along with
accompanying trial mixes as per the
relevant Clauses of these Specifications
to be submitted to the Engineer for his
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approval before use on the Works;
(v) Detailed design calculations and
drawings for all Temporary Works (such
as form-work, staging, centering;
specialised constructional handling and
launching equipment and the like);
(vi) Detailed drawings for templates, support
and end anchorage, details for
prestressing cable profiles, bar bending
and cutting schedules for reinforcement,
material lists for fabrication of structural
steel, etc;
(vii) Mill test reports for all mild and high
tensile steel and cast steel as per the
relevant provisions of the Specifications;
(viii) Testing of various finished items and
materials including bitumen, cement,
concrete, bearings as required under these
Specifications and furnishing test
reports/certificates;
(ix) Inspection Reports in respect of
formwork, staging, reinforcement and
other items of work as per the relevant
Specifications;
(x) Any other data which may be required as
per these. Specifications or the
Conditions of Contract or any other
annexures/schedules forming part of the
Contract;
(xi) Any other item of work which is not
specifically provided in the Bill of
Quantities but which is necessary for
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complying with the provisions of the
Contract;
(xii) All temporary works, formwork and false
work;
(xiii) Establishing and running a laboratory
with facilities for testing for various items
of works as specified in Section 900 and
other relevant Clauses, where there is no
separate item in the Bill of Quantities for
establishing and running a laboratory;
(xiv) Cost of in-built provisions for Quality
Assurance;
(xv) Cost of safeguarding the environment;
and
(xvi) Cost of providing “as-built drawings” in
original and two sets of prints.
114.3. Portions of road works beyond the

limits and/or any other work may be got constructed
by the Employer directly through other agencies.
Accordingly, other agencies employed by the
Employer may be working in the vicinity of the
Works being executed by the Contractor. The
Contractor shall liaise with such agencies and adjust
his
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construction programme for the completion of work
accordingly and no claim or compensation due to
any reason whatsoever will be entertained on this
account. The Employer will be indemnified by the
Contractor for any claims from other agencies on
this account.
115. METHODOLOGY AND

SEQUENCE OF WORK
Prior to start of the construction activities at

site, the Contractor shall, within 30 days after the
date of the Letter of Acceptance, submit to the
Engineer for approval, the detailed construction
methodology including mechanical equipment
proposed to be used, sequence of various activities
and schedule from start lo end of the project.
Programme relating to pavement and shoulder
construction shall be ari integrated activity to be
done simultaneously in a coordinated manner. The
methodology and the sequence shall be so planned as
to provide proper safety, drainage and free flow of
traffic.
116. CRUSHED STONE AGGREGATES
Where the terms crushed gravel/shingle,

crushed stone, broken stone or stone aggregate
appear in any part of the Tender Documents or
Drawings issued for work, they refer to crushed
gravel/crushed shingle/crushed stone aggregate
obtained from integrated crushing plant having
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appropriate primary crusher, secondary crusher and
vibratory screen.
117. APPROVAL OF MATERIALS
Approval of all sources of material for work

shall be obtained in writing from the Engineer before
their use on the project.
118. SUPPLY OF QUARRY SAMPLES
Raw and processed samples of the mineral

aggregates from the approved quarry shall be
submitted by the Contractor at no extra cost.
119. USE OF SURFACES BY CONSTRUCTION

TRAFFIC
119.1. Ordinarily, no construction traffic

shall be allowed on pavement under construction
unless authorised by the Engineer. Even in that case
the load and intensity of construction traffic should
be so regulated that no damage is caused to the
subgrade or pavement layers already constructed.
Where necessary, service roads shall be constructed
for this purpose and the same shall be considered
as incidental to the work.
119.2. The wheels or tracks of plant moving
over the various pavement courses shall be kept free
of deleterious materials.
119.3. Bituminous base course shall be kept

clean and uncontaminated as long as the same
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remains uncovered by a wearing course or surface
treatment. The only traffic permitted access to the
base course shall be that engaged in laying and
compacting the wearing course or that engaged on
such surface treatment where the base-course is to
be blinded and /or surface dressed. Should the base
course or tack coat on the base course become
contaminated, the Contractor shall make good by
clearing it to the satisfaction of the Engineer, and if
this is impracticable, by removing the layer and
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replacing it to Specification without any extra cost.
120. SITE OFFICE FOR ENGINEER AND

OTHER SUPERVISORY STAFF
120.1. Scope
The work covers the construction and

provision of furnished site office accommodation for
the supervisory staff of Engineer and maintaining the
same.
120.2. Description
The Contractor shall arrange to provide fully

furnished office accommodation constructed as
shown in drawings. Work includes providing electric
supply, all electrical items like lights, fans and
complete wiring, providing water supply including
all pipes, fittings, tanks, tube well, pumps, valves
etc. complete, septic tank, sewer lines, drains,
fencing, internal surfaced roads etc. complete as
shown on the drawings. The Contractor shall provide
the office accommodation within 4 months from the
date of the commencement of work or 3 months
from the date of providing the land and the working
drawings for the construction of office
accommodation, whichever is later. List of furniture
to be provided and maintained for Engineer’s site
office shall be as in Table 100-2.
Table 100-2. LIST OF FURNITURE TO BE
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PROVIDED AND MAINTAINED
FOR ENGINEER’S SITE OFFICE
S.No. Item Specification
01. Executive table Make - Godrej Model

(for the Engineer) No. T-108 or equivalent
02. Executive chair Make-Godrej Model

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

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

I (For the Engineer, CHR-6 or equivalent.
Accountant, Head Clerk and
visitors)
05. Table (for all other staff) Make-Godrej Model
No. T-101 or equivalent
06. Ordinary chair-Type II (for all Make-Godrej Model

other staff and visitors) No. CHR-6 or equivalent
07. Stool Maka-Godrej Model

No. ST-2 or equivalent
Page 79 of 1427
S.No. Item Specification
08. Steel Aimirah 1980mm x Make-Godrej Model

915mm x 485mm No.l Storewel plain
or equivalent
09. Steel Aimirah 1270mm x 765 Make-Godrej Model Minor
mm x 440 mm plain or equivalent
10. Racks - 5 Tier Made of slotted

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

(English & Hindi)
Network make or equivalent.
12. Steel Cash Chest Make-Godrej Storewel

of size 1.5 x 1.5 or equivalent
(450 mm x 450 mm)
(approx.)
13. Air Coolers The coolers shall have 24”

(60cm) size fan with suitable
pump and shall be of either
GEC. Khaitan or Cool
Home make or equivalent
Page 80 of 1427
14. Room Healers The heaters shall be of
2000 W capacity - Bajaj
make or equivalent
15. Ceiling Fans Ceiling fans shall be of
1400 mm size approved make and colour
16. Computer with printer PC 486 with hard disc capacit

230 MB, Maths coprocessor.
Two disc drives of 5.25” (132
mm) and 3.5” (88 mm), 14”
(350 mm) size colour VGA
monitor letter-quality dotmatr
printer of 132 columns and 10
Key board
17. Photocopier Make RICOH Model FT 4065

or equivalent
* Numbers to be decided by the Engineer as per.

requirements of the Project.
Page 81 of 1427
120.3. Ownership
The site office with all services, furniture and

fittings shall be the property of the Employer. The
land for the sites office shall be provided by -the
Engineer and the location shall be as indicated in the
Drawings.
120.4. Maintenance
The Contractor shall arrange to maintain the

site office until the issue of Taking over Certificate
for the complete work. Maintenance includes the day
to day upkeep of the building and the surroundings,
attending to repairs to various parts of the building,
furniture, fittings, office equipment and the
connected services as and when necessary, including
the periodic white/colour washing of building and
painting of wood work, steel work, replacing the
broken window/door/ventilator glasses, furniture and
other hardware and maintaining necessary watch and
ward during day and night
The Contractor shall arrange to provide
uninterrupted supply of electricity and water for the
office building. In case of failure of main
power/water supply, alternate source shall be
available for providing uninterrupted supply. All
sources, tappings and connected equipment and
fittings, piping, tanks, wiring and all accessories of
the main alternate power/water supply, for the site
office accommodation shall be the property of the
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Employer.
120.5. Measurements for Payment
The measurement for construction and

provision of site office shall be in square metres of
the plinth area of the office accommodation and the
payment shall be made after the completion and
handing over of the buildings with connected
services fully furnished including office equipment
for occupation.
If the Contractor fails to hand over the
furnished office accommodation within the period
stipulated under Clause 120.2, an amount of
Rs.15,000 per month or part thereof shall be debited
to the Contractor’s account for the period of delay.
The measurement for maintenance of
Engineer’s site office accommodation shall be on
maintenance months and shall be made on
completion of satisfactory maintenance every month.
If at any stage, the Contractor fails to carry
out the required maintenance satisfactorily, an
amount of Rs.5000 per month or part thereof shall be
debited to the Contractor’s account. In addition, the
month/months during which the Contractor fails to
carry out the required maintenance satisfactorily
shall not be measured for payment.
If the Contract works are not completed
within the stipulated period or within the granted
extended time of completion, maintenance of site
office accommodation in accordance with Clause
120.4 shall be carried out by the Contractor at his
Page 83 of 1427
own cost and as such no payment shall be made for
the same. In case of any failure by the Contractor to
do so, an amount of Rs.15,000 per month or part
thereof shall be debited to the Contractor’s account.
120.6. Rate
The Contract unit rate for constructing and

providing the site office accommodation shall
include the expenses of all the operations involved in
construction
Page 84 of 1427
of the building including all services, fittings,
fixtures, furniture, fencing, internal surfaced roads,
as mentioned under Clause 120.2.
The Contract unit rate for maintenance shall
include expenses towards all items of works detailed
in Clause 120.4 including power and water charges
for supply from the mains and for providing
uninterrupted supply of power and water from
alternate sources in case of failure of main supply.
121. FIELD LABORATORY
121.1. Scope
The work covers the provision and

maintenance of an adequately equipped field
laboratory as required for site control on the quality
of materials and the works.
121.2. Description
The Contractor shall arrange to provide fully

furnished and adequately equipped field laboratory
constructed as shown in drawings. The field
laboratory shall preferably be located adjacent to the
site office of the Engineer and provided with
amenities like water supply, electric supply etc. as
for the site office of the Engineer in Clause 120.2.
The floor space requirement for the field
laboratory shall be as indicated in the drawing. It
shall include office space for the Materials
Engineers, one from the Contractor’s side and
Page 85 of 1427
another from the Engineer’s side and a store for the
storage of samples. The remaining space shall be
provided for the installation of equipment, laboratory
tables and cupboards, working space for carrying out
various laboratory tests, besides a wash basin, toilet
facility and a curing tank for the curing of samples,
around 4m x 2m x 1m in size and a fume chamber.
The furnishing in each of two offices of the
Materials Engineers shall be as provided for the Site
Engineer in Table 100-2. Wooden/concrete working
table with a working platform area of about 1m x
10m shall be provided against the walls, also
providing wooden cupboards above and below the
working tables to store accessories such as sample
moulds etc. Atleast 4 racks of slotted angles and
M.S. sheets as at Sr.No. 10 of Table 100-2 and
atleast 6 stools for laboratory test operators as at
Sr.No 7 of Table 100-2 shall also be provided,
121.3. Laboratory Equipment
The following items of laboratory equipment

shall be provided in the field laboratory.
121.3.1. General
(i) Oven - Electrically operated,

thermostatically controlled, range
upto 200°C sensitivity 1°C
(ii) Platform balance 300 kg capacity
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(iii) Balance 20 kg capacity-self indicating type
(iv) Electronic Balance 5 kg capacity accuracy 0.5 gm

(v) Water bath-electrically operated and
thermostatically controlled with adjustable
shelves, sensitivity 1°C
(vi) Thermometers:
Mercury-in-glass thermometer range
00 to 250°C
Mercury-in-steel thermometer with 30 cm
stem, range upto 300°C
(vii) Kerosene or gas stove or electric hot plate
(viii) Glasswares, spatulas, wire gauzes,

steel scales, measuring tape, casseroles,
karahis, enamelled trays of assorted sizes,
pestle-mortar, porcelain dishes, gunny bags,
plastic bags, chemicals, digging tools like
pickaxes, shovels etc.
(ix) Set of IS sieves with lid and pan:

450 mm diameter:
63 mm, 53 mm, 37.5 mm, 26.5 mm. 13.2 mm, 9.5 mm,
6.7 mm and 4.75 mm size
200 mm diameter:
2.36 mm, 2.0 mm, 1.18 mm. 600 micron, 425 micron,
300 micron, 150 micron, and 75 micron
(x) Water testing kit
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(xi) First aid box
121.3.2. For soils and aggregates

(i) Riffle Box
(ii) Atterberg Limits (liquid and plastic
limits) determination apparatus.
The Contract lumpsum rate for the supply,

erection, maintenance and running of testing
equipment shall include cost of supply, installation
and running including all consumables like
chemicals and reagents.
122. SITE RESIDENTIAL

ACCOMMODATION FOR ENGINEER
AND
OTHER SUPERVISORY STAFF
122.1. Scope

maintenance of unfurnished site residential
accommodation for the Engineer and other
supervisory staff.
residential accommodation constructed as shown in
the drawings.
Page 88 of 1427
Work includes providing electric supply, all
electrical items like wiring, switches, all fittings,
lights, fans, etc. complete; providing water supply
and sanitation including all pipes, fittings, tanks,
tube well, pumps, valves etc. complete; septic tank,
sewer lines, drains, fencing, internal roads etc.,
complete as shown in the drawings.
122.2. Ownership
The site residential accommodation with all

services and fittings etc., shall be the property of the
Employer. The land for the residential
accommodation shall be provided by the Engineer
and the location shall be as indicated by the
Engineer. The Contractor shall provide the
residential accommodation within 4 months from the
date of commencement of the work or 3 months
from the date of providing land and the. working
drawings for the construction of residential
accommodation, whichever is later.
122.3. Maintenance

supervisory staff residential accommodation until the
issue of Taking Over Certificate for the complete
work.
Maintenance includes attending to repairs to
various parts of the building, fittings etc. and the
connected services as and when necessary, including
the annual white/colour washing of the building and
Page 89 of 1427
periodic painting of wood and steel work; replacing
the broken window/door, ventilator glasses and other
hardware; and maintenance of internal roads.
uninterrupted supply of electricity and water for the
buildings. In case of failure of main water or power
supply, suitable alternate arrangement shall be made
for providing uninterrupted supply. All
sources/tappings and connected equipment and
fittings, piping, tanks, wiring and all other
accessories of the main and alternate power/water
supply for the residential accommodation shall be
the property of the Employer.
122.4. Measurement for Payment
The measurement for construction of the

residential accommodation shall be on square metres
of plinth area of the accommodation. The payment
shall be made after the residential accommodation,
complete with all services, fencing etc., is
constructed and handed over for occupation. If the
Contractor fails to complete and hand over the
complete residential accommodation within the
period stipulated under Clause 122.2. an amount of
to the Contractor’s account for the period of delay.
The measurement for maintenance of
supervisory staff residential accommodation shall be
in maintenance months and shall be made on
completion of satisfactory maintenance every month.
If at any stage the Contractor fails to carry out the
Page 90 of 1427
required maintenance satisfactorily, an amount of
to the Contractor’s account In addition, the
month/months during which the Contractor fails to
carryout the required maintenance satisfactorily shall
not be measured for payment.
If the Contract works are not completed
extended time of completion, maintenance of resi-
dential accommodation in accordance with Clause
122.3 shall be carried out by the Contractor at his
own cost and as such no payment shall be made for
the same. In case of any failure by the Contractor
Page 91 of 1427
to do so, an amount of Rs.60,000 per month or part
thereof shall be debited to the Contractor’s account.
122.5. Rate
The Contract unit rate for constructing and

providing residential accommodation for the
Engineer and other supervisory staff shall include
cost of all the operations involved in construction of
buildings and connected services and fittings,
fencing etc. complete.
The Contract unit rate for maintenance shall
include the expenses for -all items of work detailed
in Clause 122.3 including provision pf uninterrupted
supply of power and water.
123. PROVIDING AND

MAINTAINING WIRELESS
COMMUNICATION SYSTEM
123.1. Scope

maintenance of wireless communication systems
with necessary mobile/base trans-receivers and other
accessories.
123.2. Supply
The Contractor shall arrange to supply,

install and commission the complete wireless system
of approved quality suitable for a range of upto 65
Page 92 of 1427
km. The system shall consist of the following:
(a) Mobile Trans-receiver suitable for
mounting on 4 whee’ers with
Microphone assembly. Mobile
Antenna with Cable and External
Speaker assembly (3 W audio
output) with all necessary fittings
and accessories - 10 sets.
(b) Base Trans-receivers with
Microphone assembly, suitable
Antenna, external speaker unit (3
W audio output) with all
necessary fittings and accessories
- 3 sets.
(c) Hand held radio sets - 10 Nos.
The Contractor shall provide the complete

wireless system within 12 months from the date of
commencement of work or 8 months from the date
on which frequency is allotted to him by the Govt.
Department, whichever is later. He shall submit a
guarantee for replacement of any defective trans-
receiver/trans-receivers during the currency of the
contract.
123.3. Approval
The Contractor shall arrange to obtain all

necessary statutory approvals from various
Government bodies for operating the system. He
shall also fulfil the requirements laid down by
various Government Departments and obtain the
Page 93 of 1427
frequency to operate the wireless system
Page 94 of 1427
123.4. Maintenance

entire wireless system including the mobile and base
trans-receivers and all accessories until the issue of
the Taking Over Certificate for the complete work.
H;: shall replace any Trans-receiver or accessory
which goes out of order, at his own cost and provide
all necessary spares and attend to all repairs
necessary for keeping the complete system in
satisfactory working condition. On issue of the
Taking Over Certificate after obtaining clearance
from the Engineer, the Contractor shall dismantle the
complete wireless system and hand over to the
Engineer.
The measurement for supply and installation

of wireless system, shall be on lumpsum basis for the
complete system as described in the preceding paras.
If the Contractor fails to commission and
hand over the complete wireless system in the
stipulated time, an amount of Rs.10,000 per month
or part thereof shall be debited to the Contractor’s
account
The measurement for maintenance of the
wireless system shall be on maintenance months and
shall be made on completion of satisfactory
maintenance every month. If the Contractor fails to
carry out the required maintenance as directed by the
Engineer at any stage of work, an amount of Rs.5000
Page 95 of 1427
per month or pan thereof shall be debited to the
Contractor. IB addition, the month/months during
which the Contractor fails to carry out the required
maintenance shall not be measured for payment. If
die Contract Works are not completed within the
stipulated period or within granted extended time of
completion, the maintenance of wireless system in
accordance with Clause 123.4 shall be carried out by
the Contractor at his own cost and as such, no
payment shall be-made for the same. In case of any
failure by the Contractor to do so, an amount of
Rs.8000 per month or part thereof shall be debited
10 the Contractor’s account.
123.6. Rates
The Contract unit rate for the supply and

installation of wireless system shall cover all the
expenses towards the supply of all necessary items
and expenses towards obtaining statutory approvals
and operating frequency, erection, commissioning
and handing over, guarantee for replacement of the
trans-receiver/trans-receivers (which are found
defective) during the currency of the Contract and all
other incidentals.
The Contract unit rate for the maintenance of
wireless system shall be payment in full for carrying
out periodic servicing and checking of the system,
replacement of components, attending to all
necessary repair, payment of taxes, if any, and other
incidentals to keep the complete system in
satisfactory working condition.
Page 96 of 1427
124. PROVIDING AND MAINTAINING
VEHICLES FOR THE ENGINEER
124.1. Scope
The work covers providing and maintaining

of hard top passenger cars and /or hard top jeeps for
use by the Engineer as described under the Bill of
Quantities.
Page 97 of 1427
124.2. Description
The passenger cars shall be petrol or diesel

driven and may be Ambassador or equivalent having
cylinder capacity of minimum 1400 cc. The hard top
jeeps shall be 4 W Drive either petrol or diesel
driven and may be Maruti Gypsy Model MG - 410,
Mahindra & Mahindra Jeep Model MM-540/MM-
440 or equivalent. The number of vehicles to be
provided by the Contractor shall be decided by the
Engineer at various times, out of the total provision
in the Bill of Quantities and indicated in writing.
The Contractor shall provide within one
month from the date of order by the Engineer,
vehicles as indicated above. The vehicles shall be
provided and maintained until issue of the Taking
Over Certificate for the complete Work, initially,
new vehicles shall be provided. In case of vehicles of
Indian make, a vehicle shall be replaced with a new
vehicle after a maximum run of 75,000 km or two
years whichever is earlier. In case of vehicles of
foreign make approved by the Engineer, the vehicle
shall be replaced with a new vehicle after a
maximum run of 1,00,000 km or three years
whichever is earlier. Ail necessary taxes for
operating the vehicles shall be fully paid and all
necessary papers shall be provided as required by
prevailing Motor Vehicles Act with comprehensive
insurance cover for the vehicles. The vehicles shall
be provided day and night as required by the
Engineer. The Contractor shall also make available
drivers having valid licence at such times and for
Page 98 of 1427
such duration as instructed by the Engineer.
124.3. Maintenance
The vehicles shall be maintained in a smooth

running condition. All expenses required for keeping
the vehicles in smooth running condition such as
fuel, lubrication oil and other consumables,
necessary service and maintenance, drivers, repairs
and replacement etc. are to be met by the Contractor.
In the event of any vehicle being off the road for
maintenance or on account of breakdown, the
Contractor shall provide substitute vehicle(s)
immediately. If the Contractor at any time fails to
provide vehicles) or substitute vehicle(s) as specified
above, an amount of Rs.500 per day or part thereof
for each vehicle (that the Contractor failed to
provide) shall be debited to the Contractor’s account.
Also the number of days for which the vehicle(s)
were not provided shall not be included for payment.
If the Contract Works are not completed
extended time of completion, provision and main-
tenance of vehicles in accordance with Clause 124.1
through 124.4 shall be carried out by the Contractor
at his own cost and no payment shall be made for the
same. In case of any failure by the Contractor to
do so, an amount of Rs.700 per day or part thereof
per vehicle shall be debited to the Contractor’s
account
124.4. Withdrawal of Vehicles
Page 99 of 1427
The Contractor shall withdraw particular
vehicle/vehicles for the non-use by the Engineer if
so directed by the Engineer. In such cases-the
instructions for non-use of vehicle shall be given in
writing 15 days in advance and the withdrawal of
vehicles shall not be for a period of less than 15 days
continuously at a tune.
The payment for providing and maintaining

vehicles shall be on vehicle day basis
Page 100 of 1427

for actual number of days the vehicles were provided
in satisfactory working order. No payment shall be
made for the period of withdrawal as per Clause
124.4 irrespective of the fact whether vehicle was
available or not.
124.6. Rates
The Contract unit rate for providing and

maintaining vehicles for Engineer shall include all
expenses towards providing and keeping the vehicles
in smooth running condition including taxes etc.,
mentioned in the preceding paras.
125. SUPPLY OF COLOUR RECORD

PHOTOGRAPHS AND ALBUMS
125.1. Scope
The work covers the supply of photographs,

negatives and albums to serve as a permanent record
of various stages/facets of the work needed for an
authentic documentation as approved by the
Engineer.
125.2. Description
The Contractor shall arrange to take colour

photographs at various stages/facets of the work
including interesting and novel features of the work
as desired by the Engineer. The photographs shall be
of acceptable quality and they shall be taken by a
Page 101 of 1427

professionally competent photographer with camera
having the facility to record the date of photographs
taken in the prints and negative. The Contractor shall
supply two colour prints of each of the photographs
taken to the standard postcard size mounted in
albums of acceptable quality. Also the negative in 35
mm size shall be supplied for each photograph. Each
photograph in the album shall be suitably captioned.
Supply of two copies of colour record

photographs mounted in the albums and the negative
thereof shall be measured in number of record
photographs supplied.
Supply of additional prints of colour record
photographs shall be measured in number of
additional prints supplied.
125.4. Rate
The rate for the supply of record photographs

shall include the cost of taking the photographs,
developing and obtaining colour prints, cost of
album, mounting of photographs and captioning the
same etc.
The rate for additional colour prints shall
similarly include all costs incurred.
The photographs and materials including
negatives shall form a pan of the records of the
Department and the prints of the same cannot be
supplied to anybody else or published without the
Page 102 of 1427

written permission of the Department.
Page 103 of 1427

126. SUPPLY OF VIDEO CASSETTES
126.1. Description
The work consists of taking video films of

important activities of the work as directed by the
Engineer during the currency of the project and
editing them to a video film of playing time not less
than 60 minutes and upto 180 minutes as directed by
the Engineer. It shall contain narration of the
activities in English by a competent narrator. The
edition of the video film and the script for narration
shall be as approved by the Engineer. The video
cassettes shall be of acceptable quality and the film
shall be capable of producing colour pictures.
The measurement shall be by number of sets

of edited master cassettes each with four copies
thereof.
126.3. Rates
The contract unit rate shall include all

expenses for making video films with the help of a
professionally competent photographer, editing,
narration and supplying the final edited master
cassette alongwith four copies thereof.
Page 104 of 1427

Site Clearance
200
Site Clearance
Page 105 of 1427

201. CLEARING AND GRUBBING
201.1. Scope
This work shall consist of cutting, removing

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

lines, fences, signs, monuments, buildings, pipelines,
sewers and all highway facilities within or adjacent
to the highway which are not to be disturbed shall be
protected from injury or damage. The Contractor
shall, provide and install at his own expense, suitable
safeguards approved by the Engineer for this
Page 106 of 1427

purpose.
During clearing and grubbing, the Contractor
shall take all adequate precautions against soil
erosion, water pollution, etc., and where required,
undertake additional works to that effect vide Clause
306. Before start of operations, the Contractor shall
submit to the Engineer for approval, his work plan
including the procedure to be followed for disposal
of waste materials, etc., and the schedules for
carrying out temporary and permanent erosion
control works as stipulated in Clause 306.3.
201-3. Methods, Tools and Equipments
Only such methods, tools and equipment as

are approved by the Engineer and which will not
affect the property to be preserved shall be adopted
for the Work. If the area has thick
vegetation/roots/trees, a crawler or pneumatic tyred
dozer of adequate capacity may be used for
clearance purposes. The dozer shall have ripper
attachments for removal of tree stumps. All trees,
stumps, etc., falling within excavation and fill lines
shall be cot to such depth below ground level that in
no case foil within 500 mm of the subgrade. Also, all
vegetation such as roots, under-growth, grass and
other deleterious matter unsuitable for incorporation
in the embankment/subgrade shall be removed
between fill lines to the satisfaction of the Engineer.
On areas beyond these limits, trees and stumps
required to be removed as directed by the Engineer
shall be cut down to 1 m below ground level so that
Page 107 of 1427

these do not present an unsightly appearance.
All branches of trees extending above the
trimmed as directed by the Engineer.
All excavations below the general ground
level arising out of the removal of trees, stumps, etc.,
shall be filled with suitable material and compacted
thoroughly so as to make the surface at these points
conform to the surrounding area.
Ant-hills both above and below the ground,
as are liable to collapse and obstruct free subsoil
water flow shall be removed and their workings,
which may extend to several metres, shall be
suitably treated.
Page 108 of 1427

201.4. Disposal of Materials
All materials arising from clearing and

grubbing operations shall be the property of
Government and shall be disposed of by the
Contractor as hereinafter provided or directed by the
Engineer.
Trunks, branches and stumps of trees shall be
cleaned of limbs and roots and stacked. Also
boulders, stones and other materials usable in road
construction shall be neatly stacked as directed by
the Engineer. Stacking of stumps, boulders, stones
etc., shall be done at specified spots with all lifts and
upto a lead of 1000 m.
All products of clearing and grubbing which,
in the opinion of the Engineer, cannot be used or
auctioned shall be cleared away from the roadside in
a manner as directed by the Engineer. Care shall be
taken to see that unsuitable waste materials are
disposed of in such a manner that there is no
likelihood of these getting mixed up with the
materials meant for embankment, subgrade and road
construction.
Clearing and grubbing for road embankment,

drains and cross-drainage structures shall be
measured on area basis in terms of hectares. Clearing
and grubbing of borrow areas shall be deemed to be
a part of works preparatory to embankment
construction and shall be deemed to have been
Page 109 of 1427

included in the rates quoted for the embankment
construction item and no separate payment shall be
made for the same. Cutting of trees upto 300 mm in
girth including removal of stumps and roots, and
trimming of branches of trees extending above the
roadway shall be considered incidental to the
cleanng and grubbing operations. Removal of
stumps left over after trees have been cut by any
other agency shall also be considered incidental to
the clearing and grubbing operations.
Cutting, including removal of stumps and
roots of trees of girth above 300 mm and backfilling
to required compaction shall be measured in terms of
number according to the sizes given below:-
i) Above 300 mm to 600 mm
ii) Above 600 mm to 900 mm
iii) Above 900 mm to 1800 mm
iv) Above 1800 mm
For this purpose, the girth shall be measured

at a height of 1 metre above ground or at the top of
the stump if the height of the stump is less than one
metre from the ground.
201.6. Rates
201.6.1. The Contract unit rates for the

various items of clearing and grubbing shall be
payment in full-for carrying out, the required
operations including full compensation for all
labour, materials, tools, equipment and incidentals
necessary to complete the work. These will also
Page 110 of 1427

include removal of stumps of trees less than 300 mm
in girth as well as stumps left over after cutting of
trees carried out by another agency, excavation and
back-filling to required density, where necessary,
and handling, salvaging, piling and disposing of the
cleared materials with all lifts and upto a lead of
1000 m.
Page 111 of 1427

201.6.2. The Contract unit rate for cutting
(including removal of stumps and roots) of trees of
girth above 300 mm shall include excavation and
backfilling to required compaction, handling,
salvaging, piling and disposing of the cleared
materials with all lifts and upto a lead of 1000 m.
201.6.3. Where a Contract does not include

separate items of clearing and grubbing, the same
shall be considered incidental to the earthwork items
and the Contract unit prices for the same shall be
considered as including clearing and grubbing
operations.
202. DISMANTLING CULVERTS,

BRIDGES AND OTHER
STRUCTURES/PAVEMENTS
202.1. Scope
This work shall consist of removing, as

hereinafter set forth, existing culverts, bridges,
pavements, kerbs and other structures like guard-
rails, fences, utility services, manholes, catch basins,
inlets, etc., which are in place but interfere with the
new construction or are not suitable to remain in
place, and of salvaging and disposing of the resulting
materials and back filling the resulting trenches and
pits.
Existing culverts, bridges, pavements and
other structures which are within the highway and
which are designated for removal, shall be removed
Page 112 of 1427

upto the limits and extent specified in the drawings
or as indicated by the. Engineer.
Dismantling and removal operations shall be
carried out with such equipment and in such a
manner as to leave undisturbed, adjacent pavement,
structures and any other work to be left in place.
All operations necessary for the removal of
any existing structure which might endanger new
construction shall be completed prior to the start of
new work.
202.2. Dismantling Culverts and Bridges
The structures shall be dismantled carefully

and the resulting materials so removed as not to
cause any damage to the serviceable materials to be
salvaged, the part of the structure 10 be retained and
any other properties or structures nearby.
Unless otherwise specified, the
superstructure portion of culverts/ bridges shall be
entirely removed and other parts removed below the.
ground level or as necessary depending upon the
interference they cause to the new construction.
Removal of overlying or adjacent material, if
required in connection with the dismantling of the
structures, shall be incidental to this item.
Where existing culverts/bridges arc to be
extended or otherwise incorporated in the new work,
only such part or parts of the existing structure shall
be removed as are necessary and directed by the
Engineer to provide a proper connection to the new
work. The connecting edges shall be cut, chipped
Page 113 of 1427

and trimmed to the required lines and grades without
weakening or damaging any part of the structure to
be retained. Due care should be taken to ensure that
reinforcing bars which are to be left in place so as to
project into the new work as dowels or ties arc
not injured during removal of concrete.
Pipe culverts shall be carefully removed in
such a manner as to avoid damage to the pipes.
Steel structures shall, unless otherwise
provided, be carefully dismantled in such a manner
as to avoid damage to members thereof. If specified
in the drawings or directed
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by the Engineer that the structure is to be removed in
a condition suitable for re-erection, all members
shall be match-marked by the Contractor with white
lead paint before dismantling; end pins, nuts, loose
plates, etc., shall be similarly marked to indicate
their proper location; all pins, pin holes and
machined surfaces shall be painted with a mixture of
white lead and tallow and all loose parts shall be
securely wired to adjacent members or packed in
boxes.
Timber structures shall be removed in such a
manner as to avoid damage to such timber or lumber
as is designated by the Engineer to be salvaged.
202.3. Dismantling Pavements and Other

Structures
In removing pavements, kerbs, gutters, and

other structures like guard-rails, fences, manholes,
catch basins, inlets, etc., where portions of the
existing construction are to be left in the finished
work, the same shall be removed to an existing joint
or cut and chipped to a true line with a face
perpendicular to the surface of the existing structure.
Sufficient removal shall be made to provide for
proper grades and connections with the new work as
All concrete pavements, base courses in
carriageway and shoulders etc., designated for
removal shall be broken to pieces whose volume
shall not exceed 0.02 cu. m. and stockpiled at
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designated locations if the material is to be used later
or otherwise arranged for disposal as directed (see
Clause 202.5).
202.4. Back-filling
Holes and depressions caused by dismantling

operations shall be backfilled with excavated or
other approved materials and compacted to required
density as directed by the Engineer.
202.5. Disposal of Materials
All materials obtained by dismantling shall

be the property of Government Unless otherwise
specified, materials having any salvage value shall
be placed in neat stacks of like materials within the
right-of-way, as directed by the Engineer with all
lifts and upto a lead of 1000 m.
Pipe culverts that are removed shall be
cleaned and neatly piled on the right-of-way at
points designated by the Engineer with all lifts and
lead upto 1000 m.
Structural steel removed from old structures
shall, unless otherwise specified or directed, be
stored in a neat and presentable manner on blocks in
locations suitable for loading. Structures or portions
thereof which are specified in the Contract for re-
erection shall be stored in separate piles.
Timber or lumber from old structures which
is designated by the Engineer as materials to be
salvaged shall have all nails and bolts removed
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therefrom and shall be stored in neat piles in
locations suitable for loading.
All materials obtained from dismantling
operations which, in the opinion of the Engineer,
cannot be used or auctioned shall be disposed of as
directed by the Engineer with all lifts and upto a lead
of 1000 m.
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The work of dismantling structures shall be

paid for in units indicated below by taking
measurements before and after, as applicable:
(i) Dismantling brick/stone masonry/
concrete (plain and reinforced)
cu. m.
(ii) Dismantling flexible and cement
concrete pavement
cu. m.
(iii) Dismantling steel structures
tonne
(iv) Dismantling timber structures
cu. m.
(v) Dismantling pipes, guard rails,
kerbs, gutters and fencing
linear m.
(vi) Utility services
Nos.
202.7. Rates
The Contract unit rates for the various items

of dismantling shall be paid in full for carrying out
the required operations including full compensation
for all labour, materials, tools, equipment, safeguards
and incidentals necessary to complete the work.
These will also include excavation and backfilling
where necessary to the required compaction and for
handling, salvaging, piling and disposing of the
dismantled materials within all lifts and upto a lead
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of 1000 m.
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Earthwork, Erosion Control and Drainage
300
Earthwork, Erosion Control
and Drainage
Page 120 of 1427

301. EXCAVATION FOR ROADWAY AND
DRAINS
301.1. Scope
This work shall consist of excavation,

removal and satisfactory disposal of all materials
necessary for the construction of roadway, side
drams and waterways in accordance with
requirements of these Specifications and the lines,
grades and cross-sections shown in the drawings or
88 indicated by the Engineer. It shall include the
hauling and stacking of or hauling to sites of
embankment and subgrade construction, suitable cat
materials as required, as also the disposal of
unsuitable cut materials in specified manner,
trimming and finishing of the road to specific
dimensions or as directed by the Engineer.
301.2. Classification of Excavated

Material
301.2.1. Classification : All materials

involved in excavation shall be classified by the
Engineer in the following manner:
(a) Soil
This shall comprise topsoil, turf, sand,

silt, loam, clay, mud, peat, black
cotton soil, soft shale or loose
moorum, a mixture of these and
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similar material which yields 10 the
ordinary application of pick, spade
and/or shovel, rake or other ordinary
digging implement. Removal of
gravel or any other nodular material
having dimension in any one
direction not exceeding 75 mm
occurring in such strata shall be
deemed to be covered under this
category.
(b) Ordinary Rock (not requiring
blasting)This shall include:
(i) rock types such as laterites,
shales and conglomerates,
varieties of limestone and
sandstone etc., which may be
quarried or split with crow
bars, also including any rock
which in dry state may be
hard, requiring blasting but
which, when wet, becomes
soft and manageable by means
other than blasting;
(ii) macadam surfaces such as
water bound and bitumen/tar
bound; toting of roads, paths
etc. and hard core; compact
moorum or stabilised soil
requiring grafting tool or pick
or both and shovel, closely
applied; gravel and cobble
stone having maximum
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dimension in any one
direction between 75 and 300
mm;
(iii) lime concrete, stone masonry
in lime mortar and brick work
in lime/cement mortar below
ground level, reinforced
cement concrete which may
be broken up with crow bars
or picks and stone masonry in
cement mortar below ground
level; and
(iv) boulders which do not require
blasting having maximum
dimension in any direction of
more than 300 mm, found
lying loose on the surface or
embedded in river bed, soil,
talus, slope wash and terrace
material of dissimilar origin.
(c) Hard Rock (requiring blasting)
This shall comprise:
(i) any rock or cement concrete
for the excavation of which
the use of mechanical plant
and/or blasting is required;
(ii) reinforced cement concrete
(reinforcement cut through
but not tenanted from the
concrete) below ground level;
and
(iii) boulders requiring blasting.
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(d) Hard Rock (blasting prohibited)
Hard rock requiring blasting as
described under (c) but where
blasting is prohibited for any reason
and excavation has to be carried out
by chiselling, wedging or any other
agreed method.
(e) Marshy Soil
This shall include soils like soft clays
and peats excavated below the
original ground level of marshes and
swamps and soils excavated from
other areas requiring continuous
pumping or bailing out of water.
301.2.2. Authority for classification : The

classification of excavation shall be decided by the
Engineer and his decision shall be final and binding
on the Contractor. Merely the use of explosives in
excavation will not be considered as a reason for
higher classification unless blasting is clearly
necessary in the opinion of the Engineer.
301.3. Construction Operations
301.3.1. Setting out : After the site has

been cleared as per Clause 201, the limits of
excavation shall be set out true to lines, curves,
slopes, grades and sections as shown on the
drawings or as directed by the Engineer. The
Contractor shall provide all labour, survey
instruments and materials such as strings, pegs, nails,
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bamboos, stones, lime, mortar, concrete, etc.,
required in connection with the setting out of works
and the establishment of bench marks. The
Contractor shall be responsible for the maintenance
of bench marks and other marks and stakes as long
as in the opinion of the Engineer, they are required
for the work.
301.3.2. Stripping and storing topsoil :

When so directed by the Engineer, the topsoil
existing over the sites of excavation shall be stripped
to specified depths constituting Horizon “A” and
stockpiled at designated locations for re-use in
covering embankment slopes, cut slopes, berms and
other disturbed areas where re-vegetation is desired.
Prior to stripping the topsoil, all trees, shrubs etc.
shall be removed along with their roots, with
approval of the Engineer.
301.3.3. Excavation - General : All
excavations shall be carried out in conformity with
the directions laid here-in-under and in a manner
approved by the Engineer. The work shall be so done
that the suitable materials available from excavation
are satisfactorily utilized as decided upon
beforehand.
While planning or executing excavations, the
Contractor shall take all adequate precautions against
soil erosion, water pollution etc. as per Clause 306,
and take appropriate drainage measures to keep the
site free of water in accordance with Clause 311.
The excavations shall conform to the lines,
grades, side slopes and levels shown on the drawings
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or as directed by the Engineer. The Contractor shall
not excavate outside the limits of excavation. Subject
to the permitted tolerances, any excess depth/ width
excavated beyond the specified levels/dimensions on
the drawings shall be made good at the cost of the
Contractor with suitable material of characteristics
similar to that removed and compacted to the
requirements of Clause 305.
All debris and loose material on the slopes of
cuttings shall be removed. No backfilling shall be
allowed to obtain required slopes excepting that
when boulders or
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soft materials are encountered in cut slopes, these
shall be excavated to approved depth or instructions
of the Engineer and the resulting cavities filled with
suitable material and thoroughly compacted in an
approved manner.
After excavation, the sides of excavated area
shall be trimmed and the area contoured 10 minimise
erosion and ponding, allowing for natural drainage to
take place. If trees were removed, new trees shall be
planted, as directed by the Engineer. The cost of
planting new trees shall he deemed to be incidental
to die work.
301.3.4. Methods, tools and equipment:

Only such methods, tools and equipment as
approved by the Engineer shall be adopted/used in
the work. If so desired by the Engineer, the
Contractor shall demonstrate the efficacy of the type
of equipment to be used before the commencement
of work.
301.3.5. Rock excavation : Rock, when

encountered in road excavation, shall be removed
upto the formation level or as otherwise on the
drawings. Where, however, unstable shales or other
un-materials are encountered at the formation level,
these shall be to the extent of 500 mm below the
formation level or as specified. In all cases, the
excavation operations shall be so out that at no point
on cut formation the rock protrudes above levels.
Rocks and large boulders which are likely to cause
differential settlement and also local drainage
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problems should be removed to the extent of 500
mm below the formation level in full formation
width including drains and cut through the side
drains.
Where excavation is done to levels lower
than those specified, the excess excavation shall be
made good as per Clauses 301.3.3 and 301 6 to the
satisfaction of the Engineer.
Slopes in rock cutting shall be finished to
uniform lines corresponding to slope lines shown on
the drawings or as directed by the Engineer.
Notwithstanding the foregoing, all loose pieces of
rock on excavated slope surface which move when
pierced by a crowbar shall be removed.
Where blasting is to be resorted to, the same
shall be carried out to Clause 302 and all precautions
indicated therein observed.
Where presplitting is prescribed to be done
for the establishment of a specified slope in rock
excavation, the same shall be carried out to Clause
303.
301.3.6. Marsh excavation : The

excavation of soils from marshes/ swamps shall be
carried out as per the programme approved by the
Engineer.
Excavation of marshes shall begin at one end
and proceed in one direction across the entire marsh
immediately ahead of backfilling. The method and
sequence of excavating and backfilling shall be such
as to ensure, to the extent practicable, the complete
removal or displacement of all muck from within the
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lateral limits called for on the drawings or as staked
by the Engineer, and to the bottom of the marsh, firm
support or levels indicated.
301.3.7. Excavation of road

shoulders/verge/median for widening of pavement or
providing treated shoulders: In works involving
widening of existing pavements or providing treated
shoulders, unless otherwise specified, the
shoulder/verge/median shall be removed to their full
width and to levels shown on drawings or as
indicated by the Engineer. While doing so, care shall
be taken to see that no portion of the existing
pavement designated for retention is loosened or
disturbed. If the existing pavement gets disturbed or
loosened, it shall be dismantled and cut to a regular
shape with sides vertical and the disturbed/loosened
portion removed completely and relaid as directed
by the
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Engineer, at the cost of the Contractor.
301.3.8. Excavation for surface/sub-

surface drains : Where the Contract provides for
construction of surface/sub-surface drains to Clause
309, excavation for these shall be carried out in
proper sequence with other works as approved by the
Engineer.
301.3.9. Slides : If slips, slides, over-breaks

or subsidence occur in cuttings during the process
of construction, they shall be removed at the cost of
the Contractor as ordered by the Engineer. Adequate
precautions shall be taken to ensure that during
construction, the slopes are not rendered unstable or
give rise to recurrent slides after construction. If
finished slopes slide into the roadway subsequently,
such slides shall be removed and paid for at the
Contract rate for the class of excavation involved,
provided the slides are not due to any negligence on
the pan of the Contractor. The classification of the
debris material from the slips, slides etc. shall
conform to its condition at the time of removal and
payment made accordingly regardless of its
condition earlier.
301.3.10. Dewatering : If water is met with

in the excavations due to springs, seepage, rain or
other causes, it shall be removed by suitable
diversions, pumping or bailing out and the
excavation kept dry whenever so required or
directed by the Engineer. Care shall be taken to
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discharge the drained water into suitable outlets as
not to cause damage to the works, crops or any
other property. Due to any negligence on the part
of the Contractor, if any such damage is caused, it
shall be the sole responsibility of the Contractor
to repair/restore to the original condition at his own
cost or compensate for the damage.
301.3.11. Disposal of excavated materials :

All the excavated materials shall be the property
of the Employer. The material obtained from the
excavation of roadway, shoulders, verges, drains,
cross-drainage works etc., shall be used for filling up
of (i) roadway embankment, (ii) the existing pits in
the right-of-way and (iii) for landscaping of the road
as directed by the Engineer, including levelling and
spreading with all lifts and lead upto 1000 m and
no extra payment shall be made for the same.
All hard materials, such as, hard moorum,
rubble, etc., not intended for use as above shall be
stacked neatly on specified land as directed by the
Engineer with all lifts and lead upto 1000 m.
Unsuitable and surplus material not intended
for use within the lead specified above shall also, if
necessary, be transported with all lifts and lead
beyond initial 1000 m. disposed of or used as
301.3.12. Backfilling : Backfilling of

masonry /concrete/hume pipe drain excavation shall
be done with approved material after concrete/
masonry/hume pipe is fully set and carried out in
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such a way as not to cause undue thrust on any pan
of the structure and/or not to cause differential
settlement All space between the drain walls and the
side of the excavation shall be refilled to the original
surface making due allowance for settlement, in
layers generally not exceeding 150 mm compacted
thickness to the required density, using suitable
compaction equipment such as mechanical tamper,
rammer or plate compactor as directed by the
Engineer.
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301.4. Plying of Construction Traffic
Construction traffic shall not use the cut

formation and finished subgrade without the prior
permission of the Engineer. Any damage arising out
of such use shall be made good by the Contractor at
his own expense.
301.5. Preservation of Property
The Contractor shall undertake all reasonable

precautions for the protection and preservation of
any or all existing roadside trees, drains, sewers or
other sub-surface drains, pipes, conduits and any
other structures under or above ground, which may
be affected by construction operations and which, in
the opinion of the Engineer, shall be continued in use
without any change. Safety measures taken by the
Contractor in this respect, shall be got approved
from the Engineer. However, if any of these objects
is damaged by reason .of the Contractor’s
negligence, it shall be replaced or restored to the
original condition at his expense. If the Contractor
fails to do so, within the required time as directed
by the Engineer or if, in the opinion of the Engineer,
the actions initiated by the Contractor to
replace/restore the damaged objects are not
satisfactory, the Engineer shall arrange the
replacement/ restoration directly through any
other agency at the risk and cost of the Contractor
after issuing a prior notice to the effect.
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301.6. Preparation of Cut Formation
The cut formation, which serves as a

subgrade, shall be prepared to receive the sub-
base/base course as directed by the Engineer. Where
the material in the subgrade (that is within 500 mm
from the lowest level of the pavement) has a density
less than specified in Table 300-2, the same shall be
loosened to a depth of 500 mm and compacted in
layers in accordance with the requirements of Clause
305.
Any unsuitable material encountered in the
subgrade level shall be removed as directed by the
Engineer and replaced with suitable material
compacted in accordance with Clause 305.
In rocky formations, the surface irregularities
shall be corrected and the levels brought up to the
specified elevation with granular base material as
directed by the Engineer, laid and compacted in
accordance with the respective Specifications for
these materials. The unsuitable material shall be
disposed of in accordance with Clause 301.3.11.
After satisfying the density requirements, the cut
formation shall be prepared to receive the
subbase/base course in accordance with Clauses 310
and 311 to receive the sub-base/base course.
301.7. Finishing Operations
Finishing operations shall include the work

of properly shaping and dressing all excavated
surfaces.
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When completed, no point on the slopes
shall vary from the designated slopes by more
than 150 mm measured at right angles to the except
where excavation is in rock (hard or soft) where no
shall vary more than 300 mm from the designated
slope. In no case shall any portion of the slope
encroach on the loadway.
The finished cut formation shall satisfy the
surface tolerances Described in Clause 902.
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Where directed, the topsoil removed earlier
and conserved (Clauses 301.3.2 and 305.3.3) shall be
spread over cut slopes, where feasible, berms and
other disturbed areas. Slopes may be roughened and
moistened slightly, prior to the application of topsoil,
in order to provide satisfactory bond. The depth of
topsoil shall be sufficient to sustain plant growth, the
usual thickness being from 75 mm to 100 mm.
Excavation for roadway shall be measured by

taking cross-sections at suitable intervals in the
original position before the work starts and after its
completion and computing the volumes in cu. m. the
method of average end areas for each class of
material encountered. Where it is not feasible to
compute volumes by this method of erratic location
of isolated deposits, the volumes shall be by other
accepted methods.
At the option of the Engineer, the Contractor
shall leave depth during excavations of such shape
and size and in such positions as directed so as to
indicate the original ground level as accurately as
possible. The Contractor shall see that these remain
intact till the final measurements are taken.
For rock excavation, the overburden shall be
removed first so that necessary cross-sections could
be taken for measurement Where cross sectional
measurements could not be taken due to irregular
configuration or where the rock is admixed with
other classes of materials, the volumes shall be
Page 136 of 1427

computed on the basis of stacks of excavated nibble
after making 35 per cent deduction therefrom. When
volumes are Slated in this manner for excavated
material other than rock. Suction made will be to the
extent of 16 per cent of stacked volumes. Works
involved in the preparation of cut formation shall be
measured in units indicated below :
(i) Loosening and recompacting the

... cu. m.
loosened material at subgrade
(ii) Loosening and removal of unsuitable

... cu. m.
material and replacing with a suitable
material and compacting to- required
density
(iii) Preparing rocky subgrade
... sq. m.
(iv) Stripping including storing and
... cu. m.
application of topsoil
(v) Disposal of surplus material
... cu. m.
beyond initial 1000 m lead
301.9. Rates
301.9.1. The Contract unit rates for the items

of roadway and drain excavation shall be payment in
full for carrying out the operations required for the
individual items including full compensation for :
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(i) setting out;
(ii) transporting the excavated materials
and depositing the same on sites
of embankments, spoil banks or
stacking as directed within all lifts
and lead upto 1000 m or as otherwise
specified;
(iii) trimming bottoms and slopes of
excavation;
(iv) dewatering;
(v) keeping the work free of water as per
Clause 311; and
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(vi) all labour, materials, tools,
equipment, safety measures, testing and incidentals
necessary to complete the work to Specifications.
Provided, however, where presplitting is
prescribed to achieve a specified slope in rock
excavation, the same shall be paid for vide Clause
303.5.
301.9.2. The Contract unit rate for loosening

and recompacting the loosened materials at subgrade
shall include full compensation for loosening to the
specified depth, including breaking clods, spreading
in layers, watering where necessary and compacting
to the requirements.
301.9.3. Clauses 301.9.1 and 305.8 shall

apply as regards Contract unit rate for item of
removal of unsuitable material and replacement
with suitable material respectively.
301.9.4. The Contract unit rate for item of

preparing rocky subgrade as per Clause 301.6 shall
be full compensation for providing, laying and
compacting granular base material for correcting
surface irregularities including all materials, labour
and incidentals necessary to complete the work and
all leads and lifts.
301.9.5. The Contract unit rate for the items

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

surplus ear from roadway and drain excavation shall
be full compensation for all labour, equipment, tools
and incidentals necessary on account of the
additional haul or transportation involved beyond the
initial lead of 1000 m.
302. BLASTING OPERATIONS
302.1. General
Blasting shall be carried cut in a. manner that

completes the excavation to the lines indicated in
drawings, with the least disturbance to adjacent
material. It shall be done only with the written
permission of the Engineer. All the statutory laws,
regulations, rules, etc., pertaining to the acquisition,
transport, storage, handling and use of explosives
shall be strictly followed.
The Contractor may adopt any method or
methods of blasting consistent with the safety and
job requirements. Prior to starting any phase of the
operation the Contractor shall provide information
describing pertinent blasting procedures, dimensions
and notes.
The magazine for the storage of explosives
shall be built to the designs and specifications of the
Explosives Department concerned and located at the
approved site. No unauthorized person shall be
admitted into the magazine which when not in use
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shall be kept securely locked. No matches or
inflammable material shall be allowed in the
magazine. The magazine shall have an effective
lightning conductor. The following shall be hung in
the lobby of the magazine:
(a) A copy of the relevant rules regarding
safe storage both in English and in
the language with which the
workers concerned are familiar.
(b) A statement of up-to-date stock in the
magazine.
(c) A certificate showing the last date of
testing of the lightning conductor.
Page 141 of 1427

(d) A notice that smoking is strictly
prohibited.
All explosives shall be stored in a secure

manner in compliance with all laws and ordinances,
and all such storage places shall be clearly marked.
Where no local laws or ordinances apply, storage
shall be provided to the satisfaction of the Engineer
and in general not closer than 300 m from the road
or from any building or camping area or place of
human occupancy. In addition to these, the
Contractor shall also observe the following
instructions and any further additional instructions
which may be given by the Engineer and shall be
responsible for damage to property and any accident
which may occur to workmen or the public on
account of any operations connected with the
storage, handling or use of explosives and blasting.
The Engineer shall frequently check the Contractor’s
compliance with these precautions. 302.2. Materials,
Tools and Equipment
All the materials, tools and equipment used
for blasting operations shall be of approved type.
The Engineer may specify the type of explosives to
be allowed in special cases. The fuse to be used in
wet locations shall be sufficiently water-resistant as
to be unaffected when immersed in water for 30
minutes. The rate of burning of the fuse shall be
uniform and definitely known to permit such a
length being cut as will permit sufficient time to the
firer to reach safety before explosion takes place.
Detonators shall be capable, of giving effective
Page 142 of 1427

blasting of the explosives. The blasting powder,
explosives, detonators, fuses, etc., shall be fresh and
not damaged due to dampness, moisture or any other
cause. They shall be inspected before use and
damaged articles shall be discarded totally and
removed from the site immediately.
302.3. Personnel
The blasting operation shall remain in the

charge of competent and experienced supervisor and
workmen who are thoroughly acquainted with the
details of handling explosives and blasting
operations.
302.4. Blasting Operations
The blasting shall be carried out during fixed

hours of the day preferably during the mid-day
luncheon hour or at the close of the work as ordered
in writing by the Engineer. The hours shall be made
known to the people in the vicinity. All the charges
shall be prepared by the man in charge only.
The Contractor shall notify each public utility
company having structures in proximity to the site of
the work of his intention to use explosives. Such
notice shall be given sufficiently in advance to
enable the companies to take such steps as they may
deem necessary to protect their property from injury.
In advance of any blasting work within 50 m of any
railway track or structures, the Contractor shall
notify the concerned Railway Authority of the
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location, date, time and approximate duration of
such blasting operations.
Red danger flags shall be displayed
prominently in all directions during the blasting
operations. The flags shall be planted 200 m from
the blasting site in all directions. People, except
those who actually light the fuse, shall be prohibited
from entering this area, and all persons including
workmen shall be excluded from the flagged area at
least 10 minutes before the firing, a warning siren
being sounded for the purpose.
The charge holes shall be drilled to required
depths and at suitable places. Blasting should be as
light as possible consistent with thorough leakage of
the material necessary for economic loading and
hauling. Any method of blasting which leads to
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overshooting shall be discontinued.
When blasting is done with powder, the fuse
cut to the required length shall be inserted into the
hole and the powder dropped in. The powder shall be
gently tamped with copper rods with rounded ends.
The explosive powder shall then be covered with
tamping material which shall be tamped lightly but
firmly.
When blasting is done with dynamite and
other high explosives, dynamite cartridges shall be
prepared by inserting the square cut end of a fuse
into the detonator and finishing it with nippers at the
open end, the detonator gently pushed into the
primer leaving l/3rd of the copper tube exposed
outside. The paper of the cartridge shall then be
closed up and securely bound with wire or twine.
The primer shall be housed into die explosive.
Boreholes shall be of such size that the cartridge can
easily go down. The holes shall be cleared of all
debris and explosive inserted. The space of about
200 mm above the charge shall then be gently filled
with dry clay, pressed home and the rest of the
tamping formed of any convenient material gently
packed with a wooden rammer.
At a time, not more than 10 such charges will
be prepared and fired. The man in charge shall blow
a siren in a recognised manner for cautioning the
people. All the people shall then be required to move
to safe distances. The charges shall be lighted by the
man-in-charge only. The man-in-charge shall count
the number of explosions. He shall satisfy himself
that all the charges have been exploded before
Page 145 of 1427

allowing the workmen to go back to the work site.
After blasting operations, the Contractor shall
compact the loose residual material below subgrade
and replace the material removed below subgrade
with suitable material
302.5. Misfire
In case of misfire, the following procedure

shall be observed:
(i) Sufficient time shall be allowed to
account for the delayed blast The
man-in-charge shall inspect all the
charges and determine the missed
charge.
(ii) If it is the blasting powder charge, it
shall be completely flooded with
water. A new hole shall be drilled at
about 450 mm from the old hole and
fired. This should blast the old
charge. Should it not blast the old
charge, the procedure shall be
repeated till the old charge is blasted.
(iii) In case of charges of gelignite,
dynamite, etc. the man-in-charge shall
gently remove the lamping and the
primer with the detonator. A fresh
detonator and primer shall then be
used to blast the charge.
Alternatively, the hole may be cleared
of 300 mm of tamping and the
direction then ascertained by placing
Page 146 of 1427

a slick in the hole. Another hole may
then be drilled 150 mm away and
parallel to it. This hole shall then be
charged and fired when the misfired
hole should explode at the same lime.
The man-in-charge shall at once
report to the Contractor’s office and
the Engineer all cases of misfire, the
cause of the same and what steps
were taken in connection therewith.
If a misfire has been found to be due to
defective detonator or dynamite, the whole quantity
in the box from which defective article was taken
must be sent to the authority directed by the
Engineer for inspection to ascertain whether all the
remaining materials in the box are also defective.
Page 147 of 1427

302.6. Account
A careful and day to day account of the

explosive shall be maintained by the Contractor in an
approved register and manner which shall be open to
inspection by the Engineer at all times.
303. PRESPLITTING ROCK

EXCAVATION SLOPES
303.1. General
Presplitting is defined as the establishment of

a specified excavation slope in rock by the controlled
use of explosives and blasting accessories in
properly aligned and spaced drill holes.
The presplitting technique shall be used for
forming rock excavation slopes at locations shown
on the plans or as otherwise decided by the Engineer.
Prior to starting drilling operations for

presplitting, the Contractor shall furnish the
Engineer a plan outlining the position of ail drill
holes, depth of drilling, type of explosives to be
used, loading pattern and sequence of firing. The
drilling and blasting plan is for record purposes only
and will not absolve the Contractor of his
responsibility for using proper drilling and blasting
procedures. Controlled blasting shall begin with a
short test section of a length approved by the
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Engineer. The test section shall be presplit,
production drilled and blasted and sufficient material
excavated whereby the Engineer can determine if the
Contractor’s methods have produced an acceptable
slope.
All overburden soil and weathered rock along
the top of the excavation for a distance of about 5 to
15 m beyond the drilling limits, or to the end of the
excavation, as decided by Engineer shall be removed
before drilling the presplitting holes. Particular care
and attention shall be directed to the beginning and
end of excavations to ensure complete removal of all
overburden soil and weathered rock and to expose
fresh rock to an elevation equal to the bottom of the
adjacent lift of the presplitting holes being drilled.
Slope holes for presplitting shall be drilled
along the line of the planned, slope within the
specified tolerances. The drill holes shall be not less
than 60 mm nor more than 75 mm in diameter.
Drilling operations shall be controlled by the use of
proper equipment and technique to ensure that no
hole shall deviate from the plane of the planned
slope by more than 300 mm nor shall any hole
deviate from being parallel to an adjacent hole by
more than two-third of the planned horizontal
spacing between holes.
The length of presplit holes for any
individual lift shall not exceed 9 m.
The spacing of presplit holes shall not exceed
900 mm on centres and shall be adjusted to result in
a uniform shear face between holes.
Auxiliary drill holes along the presplit line,
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not loaded or stemmed, may be ordered by the
Engineer. Except for spacing, auxiliary drill holes
shall conform to the provisions for presplit holes.
The line of production holes shall be placed
inside the presplit lines in such a manner as to avoid
damage to the presplit face.
If necessary, to reduce shatter and overbreak
of the presplit surface, the first line of the production
holes shall be drilled parallel to the slope line at the
top of the cut and at each bench level thereafter.
Page 150 of 1427

Any blasting technique, which results in
damage to the presplit surface, shall be immediately
discontinued.
No portion of any production hole shall be
drilled within 2.5 m of a presplit plane except as
approved by the Engineer. The bottom of the
production holes shall not be lower than the bottom
of the presplit holes.
A maximum offset of 600 mm will be
permitted for a construction working bench at the
bottom of each lift for use in drilling the next lower
presplitting pattern. The drilling operations shall be
adjusted to compensate for drift of previous levels
and for the offset at the start of new levels to
maintain the specified slope plane.
The maximum diameter of explosives used in
presplit holes shall not be greater than one-half the
diameter of the presplit hole.
Only standard cartridge explosives prepared
and packaged by explosive manufacturing firms
shall be used in presplit holes. These shall be fired as
recommended by the manufacturer. Ammonium
nitrate composition blasting agents will not be
permitted in presplitting operations.
Stemming may be required to achieve a
satisfactory presplit face. Stemming material shall be
dry free-running material all of which passes 11.2
mm sieve and 90 per cent of which is retained on
2.80 mm sieve. Stemmed presplit holes shall be
completely filled to the collar.
All charges in each presplitting pattern shall
be detonated simultaneously.
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303.3. Tolerances
The presplit face shall not deviate more than

300 mm from the plane passing through adjacent
drill holes, except where the character of the lock is
such that, as determined by the Engineer,
irregularities are unavoidable. When completed, the
average plane of the slopes shall conform to the
slopes indicated on the plans and no point on the
completed slopes shall vary from the designated
slopes by more than 300 mm. These tolerances shah
be measured perpendicular to the plane of the slope.
In no case shall any portion of the slope encroach on
the side drains.
As long as equally satisfactory presplit slopes
are obtained, then either the slope face maybe
presplit before drilling for production blasting or
presplitting the slope face and production blasting
may be done at the same time, provided that the
presplitting drill holes are fired with zero delay and
the production holes are delayed starting at the row
of holes farthest from the slope and progressing in
steps to the row of holes nearest the presplit line,
which row shall be delayed at least 50 milliseconds.
In either case the presplitting holes shall extend
either to the end of the excavation or for a distance
of not less than 15 m beyond the limits of the
production holes to be detonated.
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The area of presplitting to be paid for will be
measured as square metres of acceptable presplit
slope surface.
303.5. Rates
The Contract unit rate for presplitting work

shall be payment in full for carrying out the required
operations for obtaining acceptable presplit slope
surfaces. The quantity of rock excavated through the
production/presplit holes shall be paid for as per
Clause 301.9.1.
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304. EXCAVATION FOR
STRUCTURES
304.1. Scope
Excavation for structures shall consist of the

removal of material for the construction of
foundations for bridges, culverts, retaining walls,
headwalls, cutoff walls, pipe culverts and other
similar structures, in accordance with the
requirements of these Specifications and the lines
and dimensions shown on the drawings or as
indicated by the Engineer, work shall include
construction of the necessary cofferdams and cribs
their subsequent removal; all necessary sheeting,
shoring, bracing, and pumping; the removal of all
logs, stumps, grubs and other matter and
obstructions, necessary for placing the foundations;
trimming bottoms of excavations; backfilling and
clearing up the site the disposal of all surplus
material.
304.2. Classification of Excavation
All materials involved in excavation shall be

classified in accordance with Clause 301.2.
304.3.1. Setting out : After the site has been

cleared according to Clause 201, the limits of
excavation shall be set out true to lines, curves and
slopes to Clause 301.3.1.
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304.3.2. Excavation : Excavation shall be
taken to the width of die lowest step of the footing
and the sides shall be left plumb where the nature of
soil allows it. Where the nature of soil or the depth
of the trench and season of the year do not permit
vertical sides, the Contractor at his own expense
shall put up necessary shoring, strutting and planking
or cut slopes to a safer angle or both with due regard
to the safety of personnel and works and to the
The depth to which the excavation is to be
carried out shall be as shown on the drawings, unless
the type of material encountered is such as to require
changes, in which case the depth shall be as ordered
by the Engineer. Propping shall be undertaken when
any foundation or stressed zone from an adjoining
structure is within a line of 1 vertical to 2 horizontal
from the bottom of the excavation.
Where blasting is to be resorted to, the same
shall be carried out in accordance with Clause 302
and all precautions indicated therein observed.
Where blasting is likely to endanger adjoining
foundations or other structures, necessary
precautions such as controlled blasting, providing
rubber mat cover to prevent flying of debris etc. shall
be taken to prevent any damage.
304.3.3. Dewatering and protection :

Normally, open foundations shall be laid dry. Where
water is met with in excavation due to stream flow,
seepage, springs, rain or other reasons, the
Page 155 of 1427

Contractor shall take adequate measures such as
bailing, pumping, constructing diversion channels,
drainage channels, bunds, depression of water level
by well-point system, cofferdams and other
necessary works to keep the foundation trenches
dry when so required and to protect the green
concrete/masonry against damage by erosion or
sudden rising of water level. The methods to be
adopted in this regard and other details thereof
shall be left to the choice of the Contractor but
subject to approval of the Engineer. Approval of
the Engineer shall, however, not relieve the
Contractor of the responsibility for the adequacy of
dewatering and protection
Page 156 of 1427

arrangements and for the quality and safety of the
works.
Where cofferdams are required, these shall
be carried to adequate depths and heights, be safely
designed and constructed and be made as watertight
as is necessary for facilitating construction to be
carried out inside them. The interior dimensions of
the cofferdams shall be such as to give sufficient
clearance for the construction and inspection and to
permit installation of pumping equipments, etc.,
inside the enclosed area.
If it is determined beforehand that the
foundations cannot be laid dry or the situation is
found that the percolation is too heavy for keeping
the foundation dry, the foundation concrete shall be
laid under water by tremie pipe only. In case of
flowing water or artesian springs, the flow shall be
stopped or reduced as far as possible at the time of
placing the concrete.
Pumping from the interior of any foundation
enclosure shall be done in such a manner as to
preclude the possibility of the movement of water
through any fresh concrete. No pumping shall be
permitted during the placing of concrete or for any
period of at least 24 hours thereafter, unless it is
done from a suitable sump separated from the
concrete work by a watertight wall or other similar
means.
At the discretion of the Contractor, cement
grouting or other approved methods may be used to
prevent or reduce seepage and to protect the
excavation area.
Page 157 of 1427

The Contractor shall take all precautions in
diverting channels and in discharging the drained
water as not to cause damage to the works, Crops or
any other property.
304.3.4. Preparation of foundation : The

bottom of the foundation shall be levelled both
longitudinally and transversely or stepped as
directed by the Engineer. Before footing is laid, the
surface shall be slightly watered and rammed. In the
event of excavation having been deeper than that
shown on the drawings or as otherwise ordered tie
Engineer, the extra depth shall be made up with
concrete masonry of the foundation at the cost of the
Contractor as per Clause 2104.1. Ordinary filling
shall not be used for the purpose to bring the
foundation to level.
When rock or other hard strata is
encountered, it shall be freed of all soft and loose
material, cleaned and cut to a firm surface either
level and stepped as directed by the Engineer. All
seams shall be denied out and filled with cement
mortar or grout to the satisfaction of die Engineer. In
the case of excavation in rock, annular space around
footing shall be filled with lean concrete (1:3:6
nominal mix) upto the top level of rock.
If the depth of fill required is more than 1.5m
above the top of the footing, filling upto 1.5m above
top of footing shall be done with lean concrete (1:3:6
nominal mix) followed by boulders grouted with
cement.
When foundation piles are used, the
Page 158 of 1427

excavation of each pit shall be substantially
completed before beginning pile-driving operations
therein. After pile driving operations in a given pit
are completed, all loose and displaced materials
therein shall be removed to the elevation of the
bottom of the footings.
304.3.5. Slips and slip-outs : If there are any

slips or slip-outs in the excavation, these shall be
removed by the Contractor at his own cost.
304.3.6. Public safety : Near towns, villages

arid all frequented places, trenches and
foundation pits shall be securely fenced,
provided with proper caution signs and marked with
red lights at night to avoid accidents. The
Contractor shall take adequate protective
measures to see that the excavation operations do not
affect or damage adjoining structures. For safety
precautions, guidance may be taken from IS: 3764.
Page 159 of 1427

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

materials : Clause 301.3.11 shall apply.
Excavation for structures shall be measured

in cu. m. for each class of material encountered,
limited to the dimensions shown on the drawings or
as directed by the Engineer. Excavation over
increased width, cutting of slopes, shoring,
shuttering and planking shall be deemed as conven-
ience for the Contractor in executing the work and
shall not be measured and paid for separately.
Preparation of rock foundation shall be
measured in square metres. Foundation sealing,
dewatering, including pumping shall be deemed to
be incidental to the work unless separate provision is
made for in the Contract In the latter case, payment
shall be on lumpsum basis as provided in the Bill of
Page 160 of 1427

Quantities.
304.5. Rates
304.5.1. The Contract unit rate for the

items of excavation for structures shall be
payment in full for carrying out the required
operations including full compensation for :
(i) setting out;
(ii) construction of necessary cofferdams,
cribs, sheeting, shoring and bracing
and their subsequent removal;
(iii) removal of all logs, stumps, grubs and
other deleterious matter and
obstructions, for placing the
foundations including trimming of
bottoms of excavations;
(iv) foundation sealing, dewatering
including pumping when no separate
provision for it is made in the
Contract;
(v) backfilling, clearing up the site and
disposal of all surplus material within
all lift! and leads upto 000 m or as
otherwise specified; and
(vi) all labour, materials, tools,
equipment, safety measures, diversion
of traffic and incidentals necessary to
complete the work to Specification.
304.5.2. The Contract unit rate for

preparation of rock foundation shall be full
Page 161 of 1427

compensation for cutting, trimming and cleaning the
foundation surface and filling/sealing of all seams
with cement grout or mortar including all materials,
labour and incidentals required for completing the
work.
transporting material from the excavation for
structures shall be full compensation for all labour,
equipment, tools and incidentals necessary on
account of the additional haul or transportation
involved beyond the initial lead of 1000 m.
Page 162 of 1427

305. EMBANKMENT
CONSTRUCTION
305.1. General
305.1.1. Description : These Specifications

shall apply to the construction of embankments
including subgrades, earthen shoulders and
miscellaneous backfills with approved material
obtained from roadway and drain excavation, borrow
pits or other sources. All embankments, subgrades,
earthen shoulders and miscellaneous backfills shall
be constructed in accordance with the requirements
of these Specifications and in conformity with the
lines, grades, and cross-sections shown on the
drawings or as directed by the Engineer.
305.2. Materials and General

Requirements
305.2.1. Physical requirements:
305.2.1.1. The materials used in

embankments, subgrades, earthen shoulders and
miscellaneous backfills shall be soil, moorum,
gravel, a mixture of these or any other material
approved by the Engineer. Such materials shall be
free of logs, stumps, roots, rubbish or any other
ingredient likely to deteriorate or affect the stability
of the embankment/ subgrade.
The following types of material shall be
considered unsuitable for embankment:
Page 163 of 1427

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

swell and shrinkage properties (“free swelling index”
exceeding 50 per cent when tested as per IS: 2720 -
Part 40) shall not be used as a fill material. Where
an expansive clay with acceptable “free swelling
index” value is used as a fill material, subgrade and
top 500 mm portion of the embankment just below
subgrade shall be non-expansive in nature.
305.2.1.3. Any fill material with a soluble

sulphate content exceeding 1.9 grams of sulphate
(expressed as SO3) per litre when tested in
accordance with BS : 1377 Test 10, but using a 2:1
water-soil ratio shall net be deposited within 500
mm or other distance described in the Contract, of
concrete, cement bound materials or other
cementitious materials forming part of the
Page 164 of 1427

Permanent Works.
Materials with a total sulphate content
(expressed as SO3) exceeding 0.5 per cent by mass,
when tested in accordance with BS : 1377 Test 9
shall not be deposited within 500 mm, or other
distances described in toe Contract, of metallic items
forming part of the Permanent Works.
305.2.1.4. The size of the coarse material in

the mixture of earth shall ordinarily not exceed 75
mm when being placed in the embankment and 50
mm when placed in .the subgrade. However, the
Engineer may at his discretion permit the use of
material coarser
Page 165 of 1427

than this also if he is satisfied that the same will not
present any difficulty as regards the placement of fill
material and its compaction to the requirements of
these Specifications. The maximum particle size
shall not be more than two-thirds pf the compacted
layer thickness.
305.2.1.5. Ordinarily, only the materials

satisfying the density requirements given in Table
300-1 shall be employed for the construction of the
embankment and the subgrade.
TABLE 300-1. DENSITY REQUIREMENTS OF

EMBANKMENT AND SUBGRADE
MATERIALS
S. No. Type of Work Maximum laboratory
when tested as per IS
1. Embankments up to 3 metres Not less than 15.2 kN/c
height, not subjected to extensive
flooding.
2. Embankments exceeding 3 metres Not less than 16.0 kN/c

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

shoulders/verges/backfill
Notes: (1) This Table is not applicable for

lightweight fill material e.g. cinder, fly ash
Page 166 of 1427

etc.
(2) The Engineer may relax these
requirements at his discretion taking
into account the availability of
materials for construction and other
relevant factors.
(3) The material to be used in subgrade
should also satisfy design CBR at
the dry unit weight applicable as per
Table 300-2.
305.2.2. General requirements :
305.2.2.1. The materials for embankment

shall be obtained from approved sources with
preference given to materials becoming available
from nearby roadway excavation or any other
excavation under the same.
The work shall be so planned and executed
that the best available materials are saved for the
subgrade and the embankment portion just below the
subgrade.
305.2.2.2. Borrow materials : Where the

materials are to be obtained from designated borrow
areas, the location, size and shape of these areas
shall be as indicated by the Engineer and the same
shall not be opened without his written permission.
Where specific borrow areas are not designated by
the Employer/the Engineer, arrangement for locating
the source of supply of material for embankment and
subgrade as well as compliance to environmental
Page 167 of 1427

requirements in respect of excavation and borrow
areas as stipulated, from time to time by the Ministry
of Environment and Forests, Government of India
and the local bodies, as applicable, shall be the sole
responsibility of the Contractor.
Page 168 of 1427

Borrowpits along the road shall be
discouraged. If permitted by the Engineer, these
shall not be dug continuously. Ridges of not less
than 8 m width should be left at intervals not
exceeding 300 m. Small drains shall be cut through
the ridges to facilitate drainage. The depth of the pits
shall be so regulated that their bottom docs not cut
an imaginary line having a slope of 1 vertical to 4
horizontal projected from the edge of the final
section of the bank, the maximum depth in any case
being limited to 1.5 m. Also, no pit shall be dug
within the offset width from the toe of the
embankment required as per the consideration of
stability with a minimum width of 10 m.
Haulage of material to embankments or other
areas of fill shall proceed only when sufficient
spreading and compaction plant is operating at the
place of deposition.
No excavated acceptable material other than
surplus to requirements of the Contract shall be
removed from the site. Should the Contractor be
permitted to remove acceptable material from the
site to suit his operational procedure, then he shall
make good any consequent deficit of material arising
therefrom.
Where the excavation reveals a combination
of acceptable and unacceptable materials, the
Contractor shall, unless otherwise agreed by the
Engineer, carry out the excavation in such a manner
that the acceptable materials are excavated
separately for use in the permanent works without
contamination by the unacceptable materials. The
Page 169 of 1427

acceptable materials shall be stockpiled separately.
The Contractor shall ensure that he does not
adversely affect the Stability of excavation or fills
by the methods of stockpiling materials, IBC of plants
or siting of temporary buildings or structures.
The Contractor shall obtain representative
samples from each of the identified borrow areas and
have these tested at the site laboratory following a
testing programme approved by the Engineer. It shall
be ensured that the subgrade material when
compacted to the density requirements as in Table
300-2 shall yield the design CBR value of the
subgrade.
TABLE 300-2. COMPACTION

REQUIREMENTS FOR EMBANKMENT
AND SUBGRADE
Type of work/ material Relative compaction as p

of max. laboratory dry d
as per IS: 2720 (Part 8)
1. Subgnde and earthen shoulders Not less than 97

2. Embankment Not less than 95
3. Expansive Clays
a) Subgrade and 500 mm Not allowed
portion just below the subgrade
b) Remaining portion Not less than 90
of embankment
The Contractor shall at least 7 working days

before commencement of compaction submit the
Page 170 of 1427

following to the Engineer for approval:
(i) The value! of maximum dry density
and optimum moisture content
obtained in accordance with IS: 2720
(Part 7) or (Part 8), as the case may
be, appropriate for each of the fill
materials he intends to use.
(ii) A graph of density plotted against
moisture content from which each of
the values in (i) above of maximum
dry density and optimum moisture
Page 171 of 1427

content were determined.
(iii) The Dry density-moisture content -
CBR relationships for light,
intermediate and heavy compactive
efforts (light corresponding to IS:
2720 (Part 7). heavy corresponding to
IS: 2720 (Part 8) and intermediate in-
between the two) for each of the fill
materials he intends to use in the
subgrade.
Once the above information has been
approved by the Engineer, it shall form the basis for
compaction.
305.3.1. Setting out : After the site has been

cleared to Clause 201, the work shall be set out to
Clause 301.3.1. The limits of embankment/subgrade
shall be marked by fixing batter pegs on both at
regular intervals as guides before commencing the
earthwork, embankment/subgrade shall be built
sufficiently wider than the design dimension so that
surplus material may be trimmed, ensuring that the
remaining material is to the desired density and in
position specified and conforms to the specified side
slopes.
305.3.2. Dewatering : If the foundation of

the embankment is in an area with stagnant water,
and in the opinion of the Engineer it is feasible to
Page 172 of 1427

remove it, the same shall be removed by bailing out
or pumping, as directed by the Engineer and the area
of the embankment foundation shall be kept dry.
Care shall be taken to discharge the drained water so
as not to cause damage to the works, crops or any
other property. Due to any negligence on the part of
the Contractor, if any such damage is caused, it shall
be the sole responsibility of the Contractor to
repair/restore it to original condition or compensate
the damage at his own cost.
If the embankment is to be constructed under
water, Clause 305.4.6 shall apply.
305.3.3. Stripping and storing topsoil : In

localities where most of the available embankment
materials are not conducive to plant growth, or when
so directed by the Engineer, the topsoil from all
areas of cutting and from all areas to be covered by
embankment foundation shall be stripped to
specified depths not exceeding 150 mm and stored in
stockpiles of height not exceeding 2 m for covering
embankment slopes, cut slopes and other disturbed
areas where re-vegetation is desired. Topsoil shall
not be unnecessarily trafficked either before
stripping or when in a stockpile. Stockpiles shall not
be surcharged or otherwise loaded and multiple
handling shall be kept to a minimum.
305.3.4. Compacting ground supporting

embankment/subgrade: Where necessary, the
original ground shall be levelled to facilitate
placement of first layer of embankment, scarified,
Page 173 of 1427

mixed with water and then compacted by rolling so
as to achieve minimum dry density as given in Table
300-2.
In case where the difference between the
subgrade level (top of the subgrade on which
pavement rests) and ground level is less than 0.5 m
and the ground does not have 97 per cent relative
compaction with respect to the dry density as given
in Table 300-2, the ground shall be loosened upto a
level 0.5 m below the subgrade level, watered and
compacted in layers in accordance with Clauses
305.3.5 and 305.3.6 to not less than 97 per cent of
dry density as given in Table 300-2.
Page 174 of 1427

Where so directed by the Engineer, any
unsuitable material occurring in the embankment
foundation shall be removed and replaced by
approved materials laid in layers to the required
degree of compaction.
Embankment or subgrade work shall not
proceed until the foundations for
embankment/subgrade have been inspected by the
Engineer for satisfactory condition and approved.
Any foundation treatment specified for
embankments especially high embankments, resting
on suspect foundations as revealed by borehole logs
shall be carried out in a manner and to the depth as
desired by the Engineer. Where the ground on which
an embankment is to be built has any of the material
types (a) to (f) in Clause 305.2.1, at least 500 mm of
such material must be removed and replaced by
acceptable fill material before embankment
construction commences.
305.3.5. Spreading material in layers and

bringing to appropriate
moisture content
305.3.5.1. The embankment and subgrade

material shall be spread in layers of uniform
thickness not exceeding 200 mm compacted
thickness over the entire width of embankment by
mechanical means, finished by a motor grader and
compacted as per Clause 305.3.6. The motor grader
blade shall have hydraulic control suitable for initial
adjustment and maintain the same so as to achieve
Page 175 of 1427

the specific slope and grade. Successive layers
shall not be placed until the layer under construction
has been thoroughly compacted to the specified
requirements as in Table 300-2 and got approved by
the Engineer. Each compacted layer shall be
finished parallel to the final cross-section of the
embankment.
305.3.5.2. Moisture content of the material
shall be checked at the site of placement prior to
commencement of compaction; if found to be out of
agreed limits, the same shall be made good. Where
water is required to be added in such constructions,
water shall be sprinkled from a water tanker fitted
with sprinkler capable of applying water
uniformly with a controllable rate of flow to variable
widths of surface but without any flooding. The
water shall be added uniformly and thoroughly
mixed in soil by blading, discing or harrowing until a
uniform moisture content is obtained throughout the
depth of the layer.
If the material delivered to the roadbed is too
wet, it shall be dried, by aeration and exposure to the
sun, till the moisture content is acceptable far
compaction. Should circumstances arise, where
owing to wet weather, the moisture content cannot
be reduced to the required amount by the above
procedure, compaction work shall be suspended.
Moisture content of each layer of soil shall be
checked in accordance with IS: 2720 (Part 2), and
unless otherwise mentioned, shall be so adjusted,
making due allowance for evaporation losses, that at
the time of compaction it is in the range of 1 per cent
Page 176 of 1427

above to 2 per cent below the optimum moisture
content determined in accordance with IS:2720 (Part
7) or IS:2720 (Part 8) as the case may be. Expansive
clays shall however, be compacted at moisture
content corresponding to the specified dry density,
but on the wet side of the optimum moisture content
obtained from the laboratory compaction curve.
After adding the required amount of water,
the soil shall be processed by means of graders,
harrows, rotary mixers or as otherwise approved by
the Engineer until the layer is uniformly wet.
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Clods or hard lumps of earth shall be broken
to have a maximum size of 75 mm when being
placed in the embankment and a maximum size of
50 mm when being placed in the subgrade.
305.3.5.3. Embankment and other areas of

fill shall, unless otherwise required in the Contract or
permitted by the Engineer, be constructed evenly
over their full width and their fullest possible extent
and the Contractor shall control and direct
construction plant and other vehicular traffic
uniformly over them. Damage by construction plant
and other vehicular traffic shall be made good by the
Contractor with material having the same
characteristics and strength as the material had
before it was damaged.
Embankments and other areas of unsupported
fills shall not be constructed with steeper side slopes,
or to greater widths than those shown in the
Contract, except to permit adequate compaction at
the edges before trimming back, or to obtain the final
profile following any settlement of the fill and the
underlying material.
Whenever fill is to be deposited against the
face of a natural slope, or sloping earthworks face
including embankments, cuttings, other fills and
excavations steeper than 1 vertical on 4 horizontal,
such faces shall be benched as per Clause 305.4.1
immediately before placing the subsequent fill.
All permanent faces of side slopes of
embankments and other areas of fill formed shall,
subsequent to any trimming operations, be reworked
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and sealed to the satisfaction of the Engineer by
tracking a tracked vehicle, considered suitable by the
Engineer, on the slope or any other method approved
by the Engineer.
305.3.6. Compaction : Only the compaction

equipment approved by the Engineer shall be
employed to compact the different material types
encountered during construction. Smooth wheeled,
vibratory, pneumatic tyred, sheepsfoot or pad foot
rollers, etc. of suitable size and capacity as approved
by the Engineer shall be used for the different types
and grades of materials required to be compacted
either individually or in suitable combinations.
The compaction shall be done with the help
of vibratory roller of 80 to 100 kN static weight with
plain or pad foot drum or heavy pneumatic tyred
roller of adequate capacity capable of achieving
required compaction.
The Contractor shall demonstrate the efficacy
of the equipment he intends to use by carrying out
compaction trials. The procedure to be adopted for
these site trials shall first be submitted to the
Engineer for approval.
Earthmoving plant shall not be accepted as
compaction equipment nor shall the use of a lighter
category of plant to provide any preliminary
compaction to assist the use of heavier plant be taken
into account.
Each layer of the material shall be thoroughly
compacted to the densities specified in Table 300-2.
Subsequent layers shall be placed only after the
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finished layer has been tested according to Clause
903.2.2 and accepted by the Engineer. The Engineer
may permit measurement of field dry density by a
nuclear moisture/density gauge used in accordance
with agreed procedure and the gauge is calibrated to
provide results identical to that obtained from tests in
accordance with IS: 2720 (Part 28). A record of the
same shall be maintained by the Contractor.
When density measurements reveal any soft
areas in the embankment/subgrade/earthen
shoulders, further compaction shall be carried out as
directed by the Engineer. If inspite of that the
specified compaction is not achieved, the material in
the soft areas shall be removed and replaced by
approved material, compacted to the density
requirements and satisfaction of the Engineer.
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305.3.7. Drainage : The surface of the
embankment/subgrade at all times during
construction shall be maintained at such a cross fall
(not flatter than that required for effective drainage
of an earthen surface) as will shed water and prevent
ponding.
305.3.8. Repairing of damages caused by

rain/spillage of water: The soil in the affected
portion shall be removed in such areas as directed
by the Engineer before next layer is laid and refilled
in layers and compacted using appropriate
mechanical means such as small vibratory roller,
plate compactor or power rammer to achieve the
required density in accordance with Clause 305.3.6.
If the cut is not sufficiently wide for use of required
mechanical means for compaction the same shall be
widened suitably to permit their use for proper
compaction. Tests shall be carried out as directed by
the Engineer to ascertain the density requirements of
the repaired area. The work of repairing the damages
including widening of the cut, if any, shall be carried
out by the Contractor at his own cost, including the
arranging of machinery/equipment for the purpose.
305.3.9. Finishing operations : Finishing

operations shall include the work of shaping and
dressing the shoulders/verge/roadbed and side slopes
to conform to the alignment, levels, cross-sections
and dimensions shown on the drawings or as
directed by the Engineer subject to the surface
tolerance described in Clause 902. Both the upper
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and lower ends of the side slopes shall be rounded
off to improve appearance and to merge the
embankment with the adjacent terrain.
The topsoil, removed and conserved carrier
(Clause 301.3.2 and 305.3.3) shall be spread over the
fill slopes as per directions of the Engineer to
facilitate the growth of vegetation. Slopes shall be
roughened and moistened slightly prior 10 the
application of the topsoil in order to provide
satisfactory bond. The depth of the topsoil shall be
sufficient to sustain plant growth, the usual thickness
being from 75 mm to 150 mm.
Where directed, .the slopes shall be turfed
with sods in accordance with Clause 307. If seeding
and mulching of slopes is prescribed, this shall be
done to the requirement of Clause 308.
When earthwork operations have been
substantially completed, the road area shall be
cleared of all debris, and ugly scars in the
construction area responsible for objectionable
appearance eliminated.
305.4. Construction of Embankment and

Subgrade under Special Conditions
305.4.1. Earthwork for widening existing

road embankment: When an existing embankment
and/or subgrade is to be widened and its slopes are
steeper than 1 vertical on 4 horizontal, continuous
horizontal benches, each at least 300 mm wide, shall
be cut into the old slope for ensuring adequate bond
with the fresh embankment/subgrade material to be
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added. The material obtained from cutting of
benches could be utilized in the widening of the
embankment/subgrade. However, when the existing
slope against which the fresh material is to be placed
it flatter than 1 vertical on 4 horizontal, the slope
surface may only be ploughed or scarified instead of
resorting to benching.
Where the width of the widened portions is
insufficient to permit the use of conventional rollers,
compaction shall be carried out with the help of
small vibratory rollers/plate compactors/power
rammers or any other appropriate equipment
approved by the Engineer. End dumping of material
from trucks for widening operations shall be avoided
except in difficult circumstances when the extra
width is too narrow to permit the movement of any
other types of hauling equipment.
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305.4.2. Earthwork for embankment and
subgrade to be placed against sloping ground :
Where an embankment/subgrade is to be placed
against sloping ground, the latter shall be
appropriately benched or ploughed/scarified as
required in Clause 305.4.1 before placing the
embankment/subgrade material. Extra earthwork
involved in benching or due to ploughing/scarifying
etc. shall be considered incidental to the work.
For wet conditions, benches with slightly
inward fall and subsoil drains at the lowest point
shall be provided as per the drawings, before the fill
is placed against sloping ground.
Where the Contract requires construction of
transverse subsurface drain at the cut-fill interface,
work on the same shall be carried out to s 309 in
proper sequence with the embankment and subgrade
work; approved by the Engineer.
305.4.3. Earthwork over existing road

surface : Where the embankment is to be placed
over an existing road surface, the work shall carried
out as indicated below :
(i) If the existing road surface is of
granular or bituminous type and lies
within 1 m of the new subgrade level,
the same shall be scarified to a depth
of 50 mm or more if specified, so as
to provide ample bond between the
old and new material ensuring that at
least 500 mm portion below the top of
new subgrade level is compacted to
Page 184 of 1427

the desired density.
(ii) If the existing road surface is of
cement concrete type and lies within
1m of the new subgrade level the
same shall be removed completely.
(iii) If the level difference between the
existing road surface and the new
formation level is more than 1m, the
existing surface shall be permitted to
stay in place without any
modification.
305.4.4. Embankment and subgrade

around structures : To avoid interference with the
construction of abutments, wing wails or return walls
of culvert/bridge structures, the Contractor shall, at
points to be determined by the Engineer suspend
work on embankment forming approaches to such
structures, until such time as the construction of the
latter is sufficiently advanced to permit the
completion of approaches without the risk of damage
to the structure.
Unless directed otherwise, the filling around
culverts, bridges and other structures upto a distance
of twice the height of the road from the back of the
abutment shall be carried out independent of the
work on the main embankment. The fill material
shall not be placed against any abutment or wing
wall, unless permission has been given by the
Engineer but in any case not until the concrete or
masonry has been in position for 14 days. The
embankment and subgrade shall be brought up
Page 185 of 1427

simultaneously in equal layers on each side of the
structure to avoid displacement and unequal
pressure. The sequence of work in this regard shall
be got approved from the Engineer.
The material used for backfill shall not be an
organic soil or highly plastic clay having plasticity
index and liquid limit more than 20 and 40
respectively when tested according to IS : 2720 (Pan
5). Filling behind abutments and wing walls for all
structures shall conform to the general guidelines
given in Appendix 6 of IRC:78 (Standard
Specifications and Code of Practice for Road
Bridges-Section VII) in respect of the type of
material, the extent of backfill, its laying and
compaction etc. The fill material shall be deposited
in horizontal layers in loose thickness and
compacted thoroughly to the requirements of Table
300-2.
Where the provision of any filter medium is
specified behind the abutment, the same shall be laid
in layers simultaneously with the laying of fill
material. The material
Page 186 of 1427

used for filter shall conform to the requirements for
filter medium spelt out in Clause 2502/309.3.2 (B)
unless otherwise specified in the Contract.
Where it may be impracticable to use
conventional rollers, the compaction shall be carried
out by appropriate mechanical means such as small
vibratory roller, plate compactor or power rammer.
Care shall be taken to see that the compaction
equipment does not hit or come too close to any
structural member so as to cause any damage to
them or excessive pressure against the structure.
305.4.5. Construction of embankment over

ground incapable of supporting construction
equipment : Where embankment is to be
constructed across ground which will not support
the weight of repeated heavy loads of construction
equipment the first layer of the fill may be
constructed by placing successive loads of material
in a uniformly distributed layer of a minimum
thickness required to support the construction
equipment as permitted by the Engineer. The
Contractor, if so desired by him, may also use
suitable geosynthetic material to increase the
bearing capacity of the foundation. This exception to
normal procedure will not be permitted where, in the
opinion of the Engineer, the embankments could be
constructed in the approved manner over such
ground by the use-of lighter or modified equipment
after proper ditching and drainage have been
provided. Where this exception is permitted, the
selection of the material and the construction
Page 187 of 1427

procedure to obtain an acceptable layer shall be the
responsibility of the Contractor. The cost of
providing suitable traffic conditions for
construction equipment over any area of the Contract
will be the responsibility of the Contractor and no
extra payment will be made to him. The remainder
of the embankment shall be constructed as
specified in Clause 305.3.
305.4.6. Embankment construction

underwater : Where filling : or backfilling is to be
placed under water, only acceptable granular
material or rock shall be used unless otherwise
approved by the Engineer. Acceptable granular
material shall consist of graded, hard durable
particles with maximum particle size not exceeding
75 mm. The material should be non-plastic having
uniformity coefficient of not less than 10. The
material placed in open water shall be deposited by
end tipping without compaction.
305.4.7. Earthwork for high

embankment : In the case of high
embankments, the Contractor shall normally use the
material the specified borrow area. In case he
desires to use different for his own convenience, he
shall have to carry out necessary investigations and
redesign the high embankment at his own cost.
Contractor shall then furnish the soil test data and
design of high embankment for approval of the
Engineer, who reserves the right to accept or reject
it.
Page 188 of 1427

If necessary, stage construction of fills and
any controlled rates; shall be carried out in
accordance with the Contract including of
instruments and its monitoring.
Where required, the Contractor shall
surcharge embankments or other of fill with
approved material for the periods specified in the
ct If settlement of surcharged fill results in any
surcharging material, which is unacceptable for use
in the fill being surcharged, lying below formation
level, the Contractor shall remove the unacceptable
material and dispose it as per direction of the
Engineer. He shall then bring the resultant level up
to formation level with acceptable material.
305.4.8. Settlement period : Where

settlement period is specified in the Contract, the
embankment shall remain in place for the required
settlement period before
Page 189 of 1427

excavating for abutment, wingwall, retaining wall,
footings, etc., or driving foundation piles. The
duration of the required settlement period at each
location shall be as provided for in the Contract or as
305.5. Plying of Traffic
Construction and other vehicular traffic shall

not use the prepared surface of the embankment
and/or subgrade without the prior permission of the
Engineer. Any damage arising out of such use shall,
however, be made good by the Contractor at his own
expense as directed by the Engineer.
305.6. Surface Finish and Quality Control

of Work
The surface finish of construction of

subgrade shall conform to the requirements of
Clause 902. Control on the quality of materials and
works shall be exercised in accordance with Clause
903.
305.7. Subgrade Strength
305.7.1. It shall be ensured prior to actual

execution that the borrow area material to be used in
the subgrade satisfies the requirements of design
CBR.
305.7.2. Subgrade shall be compacted and
Page 190 of 1427

finished to the design strength consistent with
other physical requirements. The actual
laboratory CBR values of constructed subgrade shall
be determined on undisturbed samples cut out from
the compacted subgrade in CBR mould fitted with
cutting shoe or on remoulded samples, compacted
to the field density at the field moisture content.
Earth embankment/subgrade construction

shall be measured separately by taking cross sections
at intervals in the original position before the work
starts and after its completion and computing the
volumes of earthwork in cubic metres by the method
of average end areas.
The measurement of fill material from
borrow areas shall be the difference between the net
quantities of compacted fill and the net of suitable
material brought from roadway and drainage
excavation. For this purpose, it shall be assumed that
one cu.m. of suitable material brought to site from
road and drainage excavation forms one cu.m. of
compacted fill and all bulking or shrinkage shall be
ignored.
Construction of embankment under water
shall be measured in cu.m.
Construction of high embankment with
specified material and in specified manner shall be
measured in cu.m.
Stripping including storing and reapplication
of topsoil shall be measure cu.m.
Page 191 of 1427

Work involving loosening and recompacting
of ground supporting embankment/subgrade shall
be measured in cu. m.
Removal of unsuitable material at
embankment/subgrade foundation and replacement
with suitable material shall be measured in cu.m.
Scarifying existing granular/bituminous road
surface shall be measured in square metres.
Page 192 of 1427

Dismantling and removal of existing cement
concrete pavement shall be measured vide Clause
202.6.
Filter medium and backfill material behind
abutments, wing walls Other retaining structures
shall be measured as finished work in position in
cu.m.
305.9. Rates
305.9.1. The Contract unit rates for the items

of embankment and construction shall be payment in
full for carrying out the operations including full
compensation for:
(i) Cost of arrangement of land as a
source of supply of material of
required quantity for construction
unless provided otherwise in the
Contract;
(ii) Selling out;
(iii) Compacting ground supporting
embankment/subgrade except where
removal and replacement of
unsuitable material or loosening and
recompacting is involved;
(iv) Scarifying or cutting continuous
horizontal benches 300 mm wide on
side slopes of existing embankment
and subgrade as applicable;
(v) Cost of watering or drying of material
in borrow areas and/or embankment
and subgrade during construction as
Page 193 of 1427

required;
(vi) Spreading in layers, bringing to

appropriate moisture content and
compacting to Specification
requirements:
(vii) Shaping and dressing top and slopes
of the ‘embankment and sabgrade
including rounding of comers;
(viii) Restricted working at sites of
structures;
(ix) Working on narrow width of
embankment and subgrade;
(x) Excavation in all soils from borrow
pits/designated borrow areas
including clearing and grubbing and
transporting the material to
embankment and subgrade site with
all lifts and leads unless otherwise
provided for in the Contract;
(xi) All labour, materials, tools,
equipment and incidentals necessary
to complete the work to the
Specifications;
(xii) Dewatering; and
(xiii) Keeping the embankment/completed
formation free of water as per Clause
311.
305.9.2. In case the Contract unit rate

specified is not inclusive of all leads, the unit rate
for transporting material beyond the initial lead, as
Page 194 of 1427

specified in the Contract for construction of
embankment and subgrade shall be inclusive of full
compensation for all labour, equipment, tools and
incidentals necessary on account of the additional
haul or transportation involved beyond the
specified initial lead.
305.9.3. Clause 301.9.5 shall apply as

regards Contract unit rates for items of stripping and
storing top soil and of reapplication of topsoil.

regards Contract unit rate for the item of loosening
and recompacting the embankment/subgrade
foundation.
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305.9.5. Clauses 301.9.1 and 305.8 shall
apply as regards Contract rates for items of removal
of unsuitable material and replacement with suitable
material respectively.
305.9.6. The Contract unit rate for scarifying

existing granular/bituminous road surface shall be
payment in full for carrying out’ the required
operauons including full compensation for all labour,
materials, tools, equipment and incidentals
necessary to complete the work. This will also
comprise of handling, salvaging, stacking and
disposing of the dismantled materials within all lifts
and upto a lead of 1000 m or as otherwise specified.
305.9.7. Clause 202.7 shall apply as regards

Contract unit rate for dismantling and removal of
existing cement concrete pavement.
305.9.8. The Contract unit rate for providing

and laying filter material behind abutments shall be
operations including all materials, labour, tools,
equipment and incidentals to complete the work to
Specifications.
305.9.9. Clause 305.4,6 shall apply as

regards Contract unit rate for construction of
embankment under water.

regards Contract unit rate for construction of high
Page 196 of 1427

embankment. It shall include cost of instrumentation,
its monitoring and settlement period, where specified
in the Contract or directed by the Engineer.
306. SOIL EROSION AND SEDIMENTATION

CONTROL
306.1. Description
This work shall consist of measures as shown

on plans or as directed by the Engineer to control
soil erosion, sedimentation and water pollution,
through use of berms, dikes, sediment basins, fibre
mat, mulches, grasses, slope drains, and other
devices.
306.2. Materials
All materials shall meet commercial grade

standards and shall be approved by the Engineer
before being used in the work.
Prior to the start of the relevant construction,

the Contractor shall submit to the Engineer for
approval his schedules for carrying out temporary
and permanent erosion/sedimentation control works
as are applicable for the items of clearing and
grubbing, roadway and drainage excavation,
embankment/subgrade construction, bridges and
other structures across water courses, pavement
Page 197 of 1427

courses and shoulders. He shall also submit for
approval his proposed method of
erosion/sedimentation control on service road and
borrowpits and his plan for disposal of waste
materials. Work shall not be started until the
erosion/sedimentation control schedules and
methods of operations for the applicable construction
have been approved by the Engineer.
Page 198 of 1427

The surface area of credible earth -material
exposed by clearing and grubbing, excavation,
borrow and fill operations shall be limited to the
extent practicable. The Contractor may be directed to
provide immediate permanent or temporary erosion
and sedimentation control measures to prevent soil
erosion and sedimentation that will adversely affect
construction operations, damage adjacent properties,
or cause, contamination of nearby streams or other
water courses, lakes, reservoirs etc. Such work may
involve the construction of temporary berms, dikes,
sediment basins, slope drains and use of temporary
mulches, fabrics, mats, seeding, or other control
devices or methods as necessary to control erosion
and sedimentation. Cut and fill slopes shall be
seeded and turfed as required on the plans.
The Contractor shall be required to
incorporate all permanent erosion and sedimentation
control features into the project at .the earliest
practicable time as outlined in his accepted schedule
to minimize the need for temporary erosion and
sedimentation control measures.
Temporary erosion/sedimentation and
pollution control measures will be used to control the
phenomenon of erosion, sedimentation and pollution
that may develop during normal construction
practices, but may neither be foreseen during design
stage nor associated with permanent control features
on the Project.
Where erosion or sedimentation is likely to
be a problem, clearing and grubbing operations
should be so scheduled and performed that grading
Page 199 of 1427

operations and permanent erosion or sedimentation
control features can follow immediately thereafter if
the project conditions permit; otherwise temporary
erosion or sedimentation control measures may be
required between successive construction stages.
Under no conditions shall a large surface area of
credible earth material be exposed at one time by
clearing and grubbing or excavation without prior
The Engineer may limit the area of
excavation, borrow and embankment operations in
progress, commensurate with the Contractor’s
capability and progress in keeping the finish grading,
mulching, seeding and other such permanent erosion,
sedimentation and pollution control measures, in
accordance with the accepted schedule. Should
seasonal limitations make such coordination
unrealistic; temporary erosion/sedimentation control
measures shall be taken immediately to the extent
feasible and justified.
In the event temporary erosion,
sedimentation and pollution control measures
become necessary-due to the Contractor’s
negligence, carelessness or failure to install
permanent controls as a part of the work as
scheduled or ordered by the Engineer, these shall be
carried out at the Contractor’s own expense.
Temporary erosion, sedimentation and pollution
control work required, which is not attributed to the
Contractor’s negligence, carelessness or failure to
install permanent controls, will be performed as
ordered by the Engineer.
Page 200 of 1427

Temporary erosion, sedimentation and
pollution control may include construction work
outside the right-of-way where such work is
necessary as a result of road construction such as
borrow pit operations, service roads and equipment
storage sites.
The temporary erosion, sedimentation and
pollution control features installed by the Contractor
shall be acceptably maintained by him till these are
needed, unless otherwise agreed by the Engineer.
The soil erosion, sedimentation and pollution

control works will be measured in terms of units
specified in the Bill of Quantities for the respective
items.
Page 201 of 1427

306.5. Rates
The Contract unit rate for different items of

soil erosion, sedimentation and pollution control
works shall be payment in full for carrying out all
required operations including full compensation for
all labour, tools, equipment and incidentals to
complete the works to the Specifications.
307. TURFING WITH SODS
307.1. Scope
This work shall consist of furnishing and

laying of the live sod of perennial turf forming grass
on embankment slopes, verges (earthen shoulders) or
other locations shown on the drawings or as directed
by thee Engineer. Unless otherwise specified, the
work shall be taken up as soon as possible following
construction of the embankment, provided the
season is favourable for establishment of the sod.
307.2. Materials
The sod shall consist of dense, well-rooted

growth of permanent and desirable grasses,
indigenous to the locality where it is to be used, and
Shall be practically free from weeds or other
undesirable matter. At the time the sod is cut, the
grass on the sod shall have a length of approximately
50 mm and the sod shall have been freed of debris.
Thickness of the sod shall be as uniform as possible,
Page 202 of 1427

with some 50-80 mm or so of soil covering the
grass roots depending on the nature of the sod, so
that practically all the dense root system of the is
retained in the sod strip. The sods shall be cut in
rectangular of uniform width, not less than about 250
mm x 300 mm in size not so large that it is
inconvenient to handle and transport these without
damage. During wet weather, the sod shall be
allowed to dry sufficiently to prevent rearing during
handling and during dry weather shall be watered
before lifting to ensure its vitality and prevent the
dropping of the soil in handling.
307.3.1. Preparation of the earth bed : The

area to be sodded shall have been previously
constructed to the required slope and cross section.
Soil on the area shall be loosened, freed of all stones
larger than 50 mm size, sucks, stumps and any
undesirable foreign matter, and brought to a
reasonably fine granular texture to a depth of not less
man 25 mm for receiving the sod.
Where required, topsoil shall be spread over
the slopes. Prior to placing the topsoil, the slopes
shall be scarified to a depth which, after settlement,
will provide the required nominal depth shown on
the plans. Spreading shall not be done when the
ground is excessively wet.
Following soil preparation and top soiling,
where required, fertilizer and ground limestone when
specified shall be spread uniformly at the rate
Page 203 of 1427

indicated on the plans. After spreading, the materials
are incorporated in the soil by discing or other means
to the depths shown on the plans.
307.3.2. Placing the sods : The prepared sod

bed shall be moistened to the loosened depth, if not
already sufficiently moist, and the sod shall be
placed thereon
Page 204 of 1427

within approximately 24 hours after the same had
been cut. Each sod strip shall be laid edge to edge
and such that the joints caused by abutting ends are
staggered. Every strip, after it is snugly placed
against the strips already in position, shall be lightly
lamped with suitable wooden or metal tampers so as
to eliminate air pockets and to press it into the
underlying soil.
On side slopes steeper than 2 (horizontal) to
1 (vertical), the laying of sods shall be started from
bottom upwards. At points where water may flow
over a sodded area, the upper edges of the sod strips
shall be turned into the soil below the adjacent area
and a layer of earth placed over this followed by its
thorough compaction.
307.3.3. Staking the sods : Where the side

slope is 2 (horizontal) to 1 (vertical) or steeper and
the distance along the slope is more than 2 m, the
sods shall be staked with pegs or nails spaced
approximately 500 to 1000 mm along the
longitudinal axis of the sod strips. Stakes shall be
driven approximately plumb through the sods to be
almost flush with them.
367.3.4. Top dressing : After the sods have

been laid in position. the surface shall be cleaned of
loose sod, excess soil and other foreign material.
Thereafter, a thin layer of topsoil shall be scattered
over the surface of top dressing and the area
thoroughly moistened by sprinkling with water.
Page 205 of 1427

3073.5. Watering and maintenance : The
sods shall be watered by the Contractor for a period
of at least four weeks after laying. Watering shall be
so done as to avoid erosion and prevent damage to
sodded areas by wheels of water tanks.
The Contractor shall erect necessary warning
signs and barriers, repair or replace sodded areas
failing to show uniform growth of grass or damaged
by his operations and shall otherwise maintain the
sod at his cost until final acceptance.
Turfing with sods shall be measured as

finished work in square metres.
307.5. Rate
The Contract unit rate for turfing with sods

shall mean payment in full for carrying out all the
required operations explained above including
Compensation for
(i) furnishing all the materials to be
incorporated in the Works with all
leads and lifts; and
(ii) all labour, tools, equipments and
incidentals to complete the work in
accordance with these Specifications.
The Contract unit rate for application of
topsoil shall be as per Clause 301.9.5.
308. SEEDING AND MULCHING
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308.1. Scope
This shall consist of preparing slopes, placing

topsoil, furnishing all seeds, commercial or organic
fertilizers and mulching materials, jute netting and
placing and incorporating the same on it slopes or
other locations designated by the Engineer shown in
the Contract documents.
Page 207 of 1427

308.2. Materials
A. Seeds: The seeds shall be of

approved quality and type suitable for
the soil on which these are to be
applied, and shall have acceptable
purity and germination to
requirements set down by the
Engineer.
Fertilizer shall consist of standard
commercial materials and conform to
the trade specified Organic manure
shall be fully putrefied organic miner
such u cow dung.
Mulching materials shall consist of
straw, hay. wood shavings or
sawdust, and shall be delivered dry.
They shall be reasonably free of weed
seed and such foreign materials as
may detract from their effectiveness
as a mulch or be injurious to the plant
growth.
B. Topsoil: Topsoil shall not be obtained
from an area known to have noxious
weeds growing in it. If treated with
herbicides or sterilents, it shall be got
tested by appropriate agricultural
authority to determine the residual in
the soil. Topsoil shall not contain less
than 2 per cent and more than 12 per
cent organic matter.
C. Bituminous Emulsion: A suitable
Page 208 of 1427

grade of bituminous cutback or
emulsion used as a tie down for
mulch shall be as described in the
Contract document or as desired by
the Engineer. Emulsified bitumen
shall not contain any solvent or
diluting agent toxic to plant life.
D. Netting: Jute netting shall be undyed
jute yam woven into a uniform open
weave with approximate 2.5 cm
square openings.
Geonetting shall be made of
uniformly extruded rectangular mesh
having mesh opening of 2 cm x 2 cm.
The colour may be black or green. It
shall weigh not less than 3.8 kg per
1000 sq. m.
308.3. Seeding Operations
308.3.1. Seed-bed preparation : The area to

be seeded shall be brought to the required slope
and cross-section by filling, reshaping eroded areas
and refinishing slopes, medians etc. Topsoil shall be
evenly spread over the specified areas to the
depth shown on the plans, unless otherwise approved
by the Engineer. The seed-bed preparation shall
consist of eliminating all live plants by suitable
means using agricultural implements. All stones
150 mm in smallest dimension and larger shall be
removed. The soil shall be excavated on the contour
to a depth of 100 mm. All clods larger than 25 mm
Page 209 of 1427

in diameter shall be crushed and packed. Where
necessary, water shall then be applied. All topsoil
shall be compacted unless otherwise specified or
approved by the Engineer. Compaction shall be by
slope compactor, cleated tractor or similar
equipment approved by the Engineer. Equipment
shall be so designed and constructed as to produce
a uniform rough textured surface ready for seeding
and mulching and which will bond the topsoil to the
underlying material. The entire area shall be
covered by a minimum of 4 passes or 2 round
trips of the roller or approved equipment.
308.3.2. Fertilizer application : Fertilizer to

the required quantities shall be spread and
thoroughly incorporated into the soil surface as a
part of the seed-bed preparation.
308.3.3. Planting of seeds : All seeds shall

be planted uniformly at the approved rate.
Immediately after sowing, the area shall be raked,
dragged or otherwise treated so as
Page 210 of 1427

to cover the seeds to a depth of 6 mm.
The operation of seed sowing shall not be
performed when the ground is muddy or when the
soil or weather conditions would otherwise prevent
proper soil preparation and subsequent operations.
308.3.4. Soil moisture and watering

requirements: Soil-moisture shall exist throughout
the zone from 25 mm to at least 125 mm below the
surface at the time of planting.
Watering of the seeded areas shall be carried
out as determined by the Engineer.
308.4. Mulching, Applying Bituminous

Emulsion and Jute
Netting/ Geonetting
Within 24 hours of seeding, mulching

material mixed with organic manure shall be placed
so as to form a continuous, unbroken cover of
approximate uniform thickness of 25 mm using an
acceptable mechanical blower. Mulching material
shall be held in place and made resistant to being
‘blown away by suitable means approved by the
Engineer. When called for in the Contract
documents, mulch material shall be anchored in
place with bituminous emulsion applied at the rate of
2300 litres per hectare. Any mulch disturbed or
displaced following application shall be removed,
reseeded and remulched as specified. Jute
netting/Geonetting shall be unrolled and placed
parallel to the flow of water immediately following
Page 211 of 1427

the bringing, to finished grade, the area specified on
the plans or the placing of seed and fertilizer. Where
more than one strip is required to cover the given
areas, they shall overlap a minimum of 100 mm. Jute
netting/ Geonetting shall be held in place by
approved wire staples, pins, spikes or wooden stakes
driven vertically into the soil.
308.5. Maintenance
The Contractor shall maintain all seeded and

mulched areas until final acceptance. Maintenance
shall include protection of traffic by approved
warning signs or barricades arid repairing any areas
damaged following the seeding and mulching
operations. If mulched areas become damaged, the
area shall be reshaped and then seeded and mulched
again as originally specified.
308.6. Measurements for payment
Seeding and mulching shall be measured as

308.7. Rate
The Contract unit rate for seeding and

mulching shall be payment in full for carrying out all
for all materials, labour, tools and incidentals.
Page 212 of 1427

309. SURFACE/SUB-SURFACE
DRAINS
309.1. Scope
This work shall consist of constructing

surface and/or sub-surface drains in accordance with
the requirements of these Specifications and to the
lines, grades, dimensions and other particulars
shown on the drawings or as directed by the
Engineer. Schedule of work shall be so arranged that
the drains are completed in proper sequence with
road works to ensure that no excavation of the
completed road works is necessary subsequently or
any damage is caused to these works due to lack of
drainage.
309.2. Surface Drains
Surface drains shall be excavated to the

specified lines, grades, levels and dimensions to the
requirements of Clause 301. The excavated material
shall be removed from the area adjoining the drains
and if found suitable, utilised in
embankment/subgrade construction. All unsuitable
material shall be disposed of as directed.
The excavated bed and sides of the drains
shall be dressed to bring these in close conformity
with the specified dimensions, levels and slopes.
Where so indicated, drains shall, be lined or
turfed with suitable materials in accordance with
details shown on the drawings.
Page 213 of 1427

All works on drain construction shall be
planned and executed in proper sequence with other
works as approved by the Engineer, with a view to
ensuring adequate drainage for the area and
minimising erosion/ sedimentation.
309.3. Sub-surface Drains
309.3.1. Scope : Sub-surface drains shall be

of close-jointed perforated pipes, open-jointed
unperforated pipes, surrounded by granular material
laid in a trench or aggregate drains to drain the
pavement courses. Sub-surface drains designed using
Geosynthetics and approved by the Engineer can
also be used.
309.3.2. Materials
A. Pipe : Perforated pipe for the drains

may be of metal/asbestos cement/
cement concrete/PVC, and
unperforated pipes of vitrified
clay/cement concrete/ asbestos
cement The type, size and grade of
the pipe to be used shall be as
specified in the Contract. In no case,
however, shall the internal diameter
of the pipe be less than 100 mm.
Holes for perforated pipes shall be on
one half of the circumference only
and conform to the spacing indicated
on the drawings. Size of die holes
Page 214 of 1427

shall not ordinarily be greater than
half of D85 size of the material
surrounding the pipe, subject to being
minimum 3 mm and maximum 6 mm.
D85 stands for the size of die sieve
that allows 85 per cent of die material
to pass through it
B. Backfill material : Backfill material
shall consist of sound, tough, hard,
durable panicles of free draining
sand-gravel material or crashed stone
and shall be free of organic material,
clay balls or other deleterious matter.
Unless die Contract specifies any
particular gradings for die backfill
material or requires these to be
designed on inverted filter criteria for
filtration and permeability to die
approval of die Engineer, die backfill
material shall be provided on the
following lines:
(i) Where die soil met with in die
trench is of fine grained type
(e.g.. silt,clay or a mixture
thereof), the backfill material
shall conform to Class I
grading set out in-Table 300-
3.
(ii) Where the soil met with in die
trench is of coarse silt to
medium sand or sandy type,
the backfill material shall
Page 215 of 1427

correspond to Class II grading
of Table 300-3
(iii) Where soil met with in die
trench is gravelly sand, the
backfill material shall
correspond 10 Class III
grading of Table 300-3.
Thickness of backfill material around the
pipe shall be as shown on die drawings subject to
being at least ISO mm alround in all cases.
Geosynthetics for use with subsurface drain
shall conform to the requirements as per Section
700.
Table 300-3. GRADING REQUIREMENTS

FOR FILTER MATERIAL
Sieve Designation Per cent passing by we

Class I Class II
53 mm -- --
45 mm -- --
26.5 mm -- 100
22.4 mm -- 95-100
11.2 mm 100 48-100
5.6 mm 92-100 28-54
2.8 mm 83-100 20-35
1.4 mm 59-96 --
710 micron 35-80 6-18
355 micron 14-40 2-9
180 micron 3-15 --
90 micron 0-5 0-4
Page 216 of 1427

309.3.3. Trench excavation: Trench for
sub-surface drain shall be excavated to the specified
lines, grades and dimensions shown in the drawings
provided that width of trench at pipe level shall not
be less than 450 mm. The excavation shall begin at
the outlet end of the drain and proceed towards the
upper end. Where unsuitable material is met with at
the trench bed, the same shall be removed to such
depth as directed by the Engineer and backfilled with
approved material which shall be thoroughly
compacted to the specified degree.
309.3.4. Laying of pipe and backfilling :

Laying of pipe in the trench shall be started at the
outlet end and proceed towards the upper end, true
to the lines and grades specified. Unless otherwise
provided, longitudinal gradient of the pipe shall not
be less than 1 in 100.
Before placing the pipe, backfill material of
the required grading(s) shall be laid for full width of
the trench bed and compacted to a minimum
thickness of ISO mm or as shown on the drawings.
The pipe shall then be embedded firmly on the bed.
Perforated pipes, unless otherwise specified,
shall be placed with their perforations down to
minimise clogging. The pipe sections shall be joined
securely with appropriate coupling fittings or bands.
Page 217 of 1427

Non-perforated pipes shall be laid with joints
as close as possible with the open joints wrapped
with suitable pervious material (like double layer of
hessian, suitable Geosynthetics or some other
material of not less than 150 mm width) to permit
entry of water but prevent fines entering the pipes. In
the case of non-perforated pipes with bell end, the
bell shall face upgrade.
Upgrade end sections of the pipe installation
shall be tightly closed by means of concrete plugs or
plugs fabricated from the same material as the pipe
and securely held in place to prevent entry of soil
materials.
After the pipe installation has been
completed and approved, backfill material of the
required grading(s) (see Clause 309.3.2B) shall be
placed over the pipe to the required level in
horizontal layers not exceeding 150 mm in thickness
and thoroughly compacted. The minimum thickness
of material above the top of the pipe shall be 300
mm.
Unless otherwise provided, sub-surface
drains not located below the road pavement shall be
sealed at the top by means of 150 mm thick layer of
compacted clay so as to prevent percolation of
surface water.
3093.5. Use of geosynthetic in laying of

pipe and backfilling : After excavating the trench
for subsurface drain, the filter fabric shall be placed,
the pipe installed and the trench backfilled with
permeable material according to dimensions and
Page 218 of 1427

details shown on the plans. Surfaces to receive filter
fabric prior to placing shall be free of loose or
extraneous material and sharp objects that may
damage the filter fabric during installation. Adjacent
rolls of the fabric shall be overlapped minimum of
450 mm. The preceding roll shall overlap the
following toll in the direction the material is being
spread.
Damage to the fabric resulting from
Contractor’s vehicles, equipment or operations shall
be replaced or repaired by the Contractor at his
expense.
309.3.6. Drain outlet: The outlet for a sub-

drain shall not be under water or plugged with debris
but should be a free outlet discharging into a
stream, culvert or open ditch. The bottom of the pipe
shall be kept above high water in the ditch and the
end protected with a grate or screen. For a length of
500 mm from the outlet end, the trench for pipe
shall not be provided with granular material but
backfilled with excavated soil and thoroughly
compacted so as to stop water directly percolating-
from the backfill material around the pipe. The pipe
in this section shall not have any perforations.
309.3.7. Aggregate drains : Aggregate

drains shall be placed within the verge/shoulders
after completion of the pavement Depth, thickness
and spacing of the aggregate drains shall be as
shown on the plan.
Trenches for aggregate drains shall be
Page 219 of 1427

excavated to a minimum width of 300 mm and to the
depth shown on the plans or ordered by the
Engineer. The bottom of the trench shall be sloped to
drain and shall be free from loose particles of soil.
The trench shall be excavated so as to expose clearly
the granular pavement courses to be drained.
Aggregate for the drains shall be durable
gravel, stone or slag and shall be free from vegetable
matter and other deleterious substances. The grading
requirements are given at Table 300-4. Type B
grading may be used only where the drain is
designed to intercept surface water flowing to the
pipe and is likely to get slowly blocked. Type A
grading allows a much wider range.
Page 220 of 1427

TABLE 300-4. GRADING REQUIREMENTS
FOR AGGREGATE DRAINS
Sieve Size Per cent passing by we

Type A Type
63 mm -- 100
37.5 mm 100 85-1
19 mm -- 0-2
9.5 mm 45-100 0.5
3.35 mm 25-80 --
600 micron 8-45 --
150 micron 0-10 --
75 micron 0-5 --
Measurement for surface and sub-surface

drains shall be per running metre length of the drain.
Disposal of surplus material beyond 1000 m shall be
measured in cu. m.
309.5. Rates
The Contract unit rates for surface and

subsurface drains shall be payment in full for all
items such as excavation, dressing the sides and
bottom; providing lining, turfing, pitching, masonry,
concrete and plastering; providing, laying and
jointing pipes; providing, laying and compacting
backfill and bed of granular material; providing,
fixing and painting of cover etc. including full
compensation for all materials, labour, tools,
Page 221 of 1427

equipment and other incidentals to complete the
work as shown on drawings with all leads and lifts
except for removal of unsuitable material for which
the lead shall be 1000 m. Provision of inlets,
gratings, sumps, outlet pipes, bedding, disbursers
etc. wherever required shall be incidental lo
construction of drain. The Contract unit rate for
disposal of surplus and unsuitable material beyond
the initial 1000 m lead shall be in accordance with
Clause 304.5.3.
310. PREPARATION AND SURFACE

TREATMENT OF
FORMATION
Preparation and surface treatment of (he

formation, that is top of the subgrade, shall be
carried out only after completion of any specified
subgrade drainage and unless otherwise agreed by
the Engineer, immediately prior to laying the sub-
base or the road base where no sub-base is required.
The sequence of operations shall be as follows:
(a) All surfaces below carriageway,
laybyes, footways and hard shoulders
shall, after reinstatement of any soft
areas to the required Specification; be
well cleaned and freed of mud and
slurry.
(b) The surface shall be compacted by 4
passes of a smooth wheeled roller of
80 to 100 kN weight after spraying
requisite amount of water, if required,
Page 222 of 1427

before the commencement of rolling.
(c) The formation shall, wherever
necessary, be regulated and
trimmed to the requirements of
Clause 305.3.9 with motor grader.
(d) The trimmed formation shall be rolled
by one pass of smooth wheeled
roller of 80 to 100 kN weight after
spraying requisite amount of water, if
required, before the commencement
of rolling.
Page 223 of 1427

Where the completed formation is not
immediately covered with sub-base or road base
material, its moisture content shall be maintained to
prevent cracking in the formation by suitable
measures as approved by the Engineer. The entire
work of surface treatment of formation shall be
deemed as incidental to the work of sub-base/base
course to be provided on the subgrade and as such no
extra payment shall be made for the same.
311. WORKS TO BE KEPT FREE OF

WATER
311.1. The Contractor shall arrange for the

rapid dispersal of water collected/accumulated on the
earthwork or completed formation during
construction or on the existing roadway or which
enters the earthwork or any other item of work
from any source, and where practicable, the water
shall be discharged into the permanent outfall of the
drainage system. The arrangements shall be made in
respect of all earthwork including excavation for
pipe trenches, foundations or cuttings.
311.2. The Contractor shall provide, where

necessary, temporary water courses, ditches, drains,
pumping or other means for maintaining the
earthwork free from water. Such provisions shall
include carrying out the work of forming the cut
sections and embankments in such manner that their
surfaces have at all times a sufficient minimum
Page 224 of 1427

crossfall and, where practicable, a sufficient
longitudinal gradient to enable them to shed water
and prevent ponding.
The works involved in keeping the earthwork
or any other item of works free of water shall be
deemed as incidental to the respective item of work
and as such no separate payment shall be made for
the same.
312. WATER COURSES AT CULVERTS
312.1. Excavation carried out in the

diversion, enlargement, deepening or straightening
water courses at culverts, where necessary, shall
include the operations such as clearing, grubbing,
removal of vegetation, trimming of slopes, grading
of beds, disposal of excavated materials, pumping,
timbering etc. necessary for dealing with the flow of
water.
312.2. The beds and sloping sides of water

courses shall, where shown on the Drawings, be
protected against the action of water by rubble
paving to form a flat or curved surface as
indicated. The protection shall consist of large
smooth faced stones or of blocks of precast concrete.
Stones for nibble paving shall be roughly dressed
square. No stone shall be less than 255 mm in depth
nor less than 0.02 cu. m. in volume and no rounded
boulders shall be used. After completion of
construction of culverts, temporary diversion of
watercourse, if any, shall be closed and water course
Page 225 of 1427

restored for flow through the culvert as per the
direction of the Engineer.
The work for water courses at culverts as

stated above shall be measured in terms of units
specified in the Bill of Quantities for respective
items. The temporary diversion of channel to
facilitate construction of Culverts, its closure and
restoration to original water course shall be
considered incidental to the work of construction of
culverts and no extra payment shall be made for the
same.
Page 226 of 1427

312.4. Rates
The Contract unit rates for different items for

water courses at culverts shall be payment in full for
carrying out all required operations including full
compensation for all cost of materials, labour, tools,
equipment and other incidentals to complete the
work to the Specification.
313. CONSTRUCTION OF ROCKFILL

EMBANKMENT
313.1. Scope
In normal circumstances, the embankment

should not be constructed with rockfill material.
However, where specifically permitted by the En-
gineer because of imperative economic or technical
reasons, construction of rockfill embankments shall
be in accordance with the lines, grades and cross-
sections as shown in drawings or as directed by the
Engineer.
Rockfill shall not be used at least for a depth
of 500 mm below the formation level. There should
be a minimum of 500 mm thick earthen cushion over
the rockfill.
313.2. Material
The size of rock pieces used in rockfill

embankments shall be such that they can be
deposited in layers so as to suit the conditions
Page 227 of 1427

evaluated in the field compaction trials or as directed
by the Engineer, rockfill shall consist of hard,
durable and inert material, preferably maximum size
not exceeding 300 mm and per cent finer than 125
mm exceeding 10 per cent.
Argillaceous rocks (clay, shales etc.), unburnt
colliery stock and chalk shall not be used in rockfill.
The rock fragments and blinding material
required for filling the voids shall also satisfy the
above requirements.
313.3. Spreading and Compaction
The material shall be tipped, spread and

levelled in layers extending 10 the full width of
embankment by a suitable dozer. Fragments of rock
shall then be spread on the top of layer to the
required extent and layer compacted by minimum of
5 passes of vibratory roller having static weight 8-10
tonnes. The compacted thickness of each layer shall
not exceed 500 mm. After compaction of each layer,
the surface voids shall be filled with broken
fragments. Next layer, where required, shall be
placed in the same manner, above the earlier
compacted layer.
The top layer of rockfill, on which normal
earth fill will rest shall be thoroughly blinded with
suitable granular material to seal its surface.
Measurement shall be made by taking cross-
Page 228 of 1427

sections at intervals in the original position before
the work starts and after its completion and
computing- the volume in cu.m. by the method of
average end areas.
Page 229 of 1427

313.5. Rate
The Contract unit rate shall be paid in full

for carrying out all the above operations including
cost of rockfill, broken fragments and material and
shall provide full compensation for all items as
Clause 305.9.1 and 305.9.2.
Page 230 of 1427

Sub-Bases, Bases (Non-
Bituminous) and Shoulders
400
Sub-Bases, Bases (Non-
Bituminous) and Shoulders
Page 231 of 1427

401. GRANULAR SUB-BASE
401.1. Scope
This work shall consist of laying and

compacting well-graded material on prepared
subgrade in accordance with the requirements of
these Specifications. The material shall be laid in
one or more layers as sub-base or lower sub-base
and upper sub-base (termed as sub-base hereinafter)
as necessary according to lines, grades and cross-
sections shown on the drawings or as directed by the
Engineer.
401.2. Materials
401.2.1. The material to be used for the work

shall be natural sand, moorum, gravel, crushed stone,
or combination thereof depending upon the grading
required. Materials like crushed slag, crushed
concrete, brick metal and kankar may be allowed
only with the specific approval of the Engineer.
The material shall be free from organic or other
deleterious constituents and conform to one of the
three gradings given in Table 400-1.
While the gradings in Table 400-1 are in
respect of close-graded granular sub-base materials,
one each for maximum particle size of 75 mm, 53
mm and 26.5 mm, the corresponding gradings for the
coarse-graded materials for each of the three
maximum particle sizes are given at Table 400-2.
The grading to be adopted for a project shall be as
Page 232 of 1427

specified in the Contract.
401.2.2. Physical requirements: The

material shall have, a 10 per cent fines value of 50
kN or more (for sample in soaked condition) when
tested in compliance with BS:812 (Part 111). The
water absorption value of the coarse aggregate shall
be determined as per IS : 2386 (Pan 3); if this value
is greater than 2 per cent, the soundness test shall
be carried out on the material delivered to site as
per IS : 383. For Grading II and III materials, the
CBR shall be determined at the density and moisture
content likely to be developed in equilibrium
conditions which shall be taken as being the density
relating to a uniform air voids content of 5 per cent.
TABLE 400-1. GRADING FOR CLOSE-

GRADED GRANULAR
SUB-BASE MATERIAL
Sieve Designation Per cent passing by IS
Grading I Grading II
75.0 mm 100 --
53.0 mm 80-100 100
26.5 mm 55-90 70-100
9.50 mm 35-65 50-80
4.75 mm 25-55 40-65
2.36 mm 20-40 30-50
0.425 mm 10-25 15-25
0.075 mm 3-10 3-10
CBR Value (Minimum) 30 25
Page 233 of 1427

TABLE 400-2. GRADING FOR COARSE
GRADED GRANULAR
SUB-BASE MATERIAL
Sieve Designation Per cent passing by IS

Grading I Grading II
75.0 mm 100 --
53.0 mm -- 100
26.5 mm 55-75 50-80
9.50 mm -- --
4.75 mm 10-30 15.35
2.36 mm -- --
0.425 mm -- --
0.075 mm <10 <10
CBR Value (Minimum) 30 25
Note : The material passing 425 micron (0.425 mm)

sieve fur all the three grading when tested
according to IS : 2720 (Part 5) shall have
liquid limit and plasticity index not more
than 25 and 6 per cent respectively.
401.3. Strength of sub-base
It shall be ensured prior to actual execution

that the material to be used in the sub-base satisfies
the requirements of CBR and other physical
requirements when compacted and finished.
When directed by the Engineer, this shall be
verified by performing CBR tests in the laboratory as
required on specimens remoulded at field dry density
and moisture content and any other tests for the
Page 234 of 1427

“quality” of materials, as may be necessary.
401.4.1. Preparation of subgrade :

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

sub-base material of grading specified in the.
Contract shall be spread on the prepared subgrade
with the help of a motor grader of adequate capacity,
its blade having hydraulic controls suitable for initial
adjustment and for maintaining the required slope
and grade during the operation or other means as
approved by the Engineer.
When the sub-base material consists of
combination of materials mentioned in Clause
401.2.1, mixing shall be done mechanically by the
mix-in-place method.
Manual mixing shall be permitted only where
the width of laying is not adequate for mechanical
operations, as in small-sized jobs. The equipment
used for mix-in-place construction shall be a
rotavator or similar approved equipment capable of
mixing the material to the desired degree. If so
desired by the Engineer, trial runs with the
equipment shall be carried out to establish its
Page 235 of 1427

suitability for the work.
Moisture content of the loose material shall
be checked in accordance with IS:2720 (Part 2) and
suitably adjusted by sprinkling additional water from
a truck mounted or trailer mounted water tank and
suitable for applying water uniformly and at
Page 236 of 1427

ontrolled quantities to variable widths of surface or
other means approved by the Engineer so that, at the
time of compaction, it is from 1 per cent above to 2
per cent below the optimum moisture content
corresponding to IS:2720 (Pan 8). While adding
water, due allowance shall be made for evaporation
losses. After water has been added, the material shall
be processed by mechanical & other approved means
like disc harrows, rotavators until the layer is
uniformly wet.
Immediately thereafter, rolling shall start. If
the thickness of the compacted layer does not
exceed1 100 mm, a smooth wheeled roller of 80
100 kN weight may be used. For a compacted single
layer upto 215 mm the compaction shall be done
with the help of a vibratory roller minimum 80 to
100 kN static weight with plain drum or pad foot-
drum or heavy pneumatic tyred roller of minimum
200 to 300 kN weight a minimum tyre pressure of
0.7 MN/m2 or equivalent capacity capable of
achieving the required compaction. Rolling shall
commence at the lower edge and proceed towards
the upper edge longitudinally for portions having
unidirectional crossfall and super-elevation and
shall commence at the edges and progress
towards the centre for portions having crossfall on
both sides.
Each pass of the roller shall uniformly
overlap not less than one-third of the track made in
the preceding pass. During rolling, the grade and
crossfall (camber) shall be checked and any high
spots or depressions which become apparent,
Page 237 of 1427

corrected by removing or adding fresh material. The
speed of the roller shall not exceed 5 km per hour.
Rolling shall be continued till the density
achieved is at least 98 per cent of the maximum dry
density for the material determined as per IS:2720
(Part 8). The surface of any layer of material on
completion of compaction shall be well closed, free
from movement under compaction equipment and
from compaction planes, ridges, cracks or loose
material. All loose, segregated or otherwise defective
areas shall be made good to the full thickness of
layer and re-compacted.
401.5. Surface Finish and Quality

Control of Work
The surface finish of construction shall

conform to the requirements of Clause 902.
Control on the quality of materials and works
shall be exercised by the Engineer in accordance
with Section 900.
401.6. Arrangements for Traffic
During the period of construction,

arrangement of traffic shall be maintained in
accordance with Clause 112.
Granular sub-base shall be measured as

finished work in position in cubic metres.
Page 238 of 1427

The protection of edges of granular sub-base
extended over the full formation as shown in the
drawing shall be considered incidental to the work of
providing granular sub-base and as such no extra
payment shall be made for the same.
Page 239 of 1427

401.8. Rate
The Contract unit rate for granular sub-base

operations including full compensation for :
(i) malting arrangements for traffic to
Clause 112 except for initial
treatment to verges, shoulders and
construction of diversions;
(ii) furnishing all materials to be
incorporated in the work including all
royalties, fees, rents where necessary
and all leads and lifts;
(iii) all labour, tools, equipment and
incidentals to complete the work to
the Specifications;
(iv) carrying out the work in part
widths of road where directed; and (v)
carrying out the required test for
quality control.
402. LIME TREATED SOIL FOR

IMPROVED SUB-GRADE/SUB-BASE
402.1. Scope

compacting an improved sub-grade/lower sub-base
of soil treated with lime on prepared sub-grade in
accordance with the requirements of these
Specifications and in conformity with the lines,
grades and cross-sections shown on the drawings or
Page 240 of 1427

as directed by the Engineer. Lime treatment is
generally effective for soils which contain a
relatively high percentage of clay and silty clay.
402.2. Materials
402.2.1. Soil : Except when otherwise

specified, the soil used for stabilisation shall be the
local clayey soil having a plasticity index greater
than 8.
402.2.2. Lime : Lime for lime-soil

stabilisation work shall be commercial dry lime
slaked at site or pre-slaked lime delivered to the site
in suitable packing. Unless otherwise permitted by
the Engineer, the lime shall have purity of net less
than 70 per cent by weight of Quicklime (CaO)
when tested in accordance with IS :1514. Lime shall
be properly stored to avoid prolonged exposure to
the atmosphere and consequent carbonation which
would reduce its binding properties.
402.2.3. Quantity of lime in stabilised mix :

Quantity of lime to be added as percentage by
weight of the dry soil shall be as specified in the
Contract. The quantity of lime used shall be related
to its calcium oxide content which shall be specified.
Where the lime of different calcium oxide content is
to be used, its quantity shall be suitably adjusted to
the approval of the Engineer so that equivalent
calcium oxide is incorporated in the work. The mix
design shall be done to arrive at the appropriate
quantity of lime to be added, having due regard to
Page 241 of 1427

the purity of lime, the type of soil, the moisture-
density relationship, and the design
CBR/Unconfined Compressive Strength (UCS)
value specified in the Contract. The laboratory
CBR/UCS value shall be at least 1.5 times the
minimum field value of CBR.AJCS stipulated in the
Contract.
402.2.4. Water : The water to be used for

lime stabilisation shall be clean and free from
injurious substances. Potable water shall be
preferred.
Page 242 of 1427

402.3.1. Weather limitations : Lime-soil

stabilisation shall not be one when the air
temperature in the shade is less than 10° C.
402.3.2. Degree of pulverisation: For lime

stabilisation, the soil before addition of stabiliser,
shall be pulverised using agricultural implements
like disc harrows and rotavators to the extent that it
passes the requirements set out in Table 400-3
when tested in accordance vith the method
described in Appendix 3.
TABLE 400-3. SOIL PULVERISATION

REQUIREMENTS FOR LIME
STABILISATION
IS Sieve designation Minimum per cent by
weight passing the IS
Sieve
26.5 mm 100
5.6 mm 80
402.3.3. Equipment for construction:

Stabilised soil sub-bases shall be constructed by
mix-in-place method of construction 01 as otherwise
approved by the Engineer. Manual mixing shall be
permitted only where the width of laying is not
adequate for mechanical operations, as in small-
sized jobs.
The equipment used for mix-in-place
construction shall be a rotavator or similar approved
Page 243 of 1427

equipment capable of pulverising and mixing the soil
with additive and water to specified degree to the
full thickness of the layer being processed, and of
achieving the desired degree of mixing and
uniformity of the stabilised material. If so desired by
the Engineer, trial runs with the equipment shall be
carried out to establish its suitability for work.
The thickness of any layer to be stabilised
shall be not less than 100 mm when compacted. The
maximum thickness shall be 200 mm, provided the
plant used is accepted by the Engineer.
402.3.4. Mix-in-place method of

construction: Before deploying the equipment, the
soil after it is made free of undesirable vegetation or
other deleterious matter shall be spread uniformly on
the prepared subgrade in a quantity sufficient to
achieve the desired compacted thickness of the
stabilised layer. Where single-pass equipment is to
be employed, the soil shall be lightly rolled at the
discretion of the Engineer.
The equipment used shall either be of single-
pass or multiple pass The mixers shall be equipped
with an appropriate device for controlling the depth
of processing and the mixing blades shall be
maintained or reset periodically so that the correct
depth of mixing is obtained at all times.
With single-pass equipment the forward
speed of the machine shall be so selected in relation
to the rotor speed that the required degree of mixing,
pulverisation and depth of processing is obtained. In
multiple-pass processing, the prepared subgrade
Page 244 of 1427

shall be pulverised to the required depth with
successive passes of the equipment and the moisture
content adjusted to be within prescribed limits
mentioned hereinafter. The blending or stabilising
material shall then be spread uniformly and mixing
continued, with successive passes until the required
depth and uniformity of processing have been
obtained.
The mixing equipment shall be so set that it
cuts slightly into the edge of the adjoining lane
processed previously so as to ensure that all the
material forming a layer has been properly processed
for the full width.
Page 245 of 1427

402.3.5. Construction with manual means:
Where manual mixing is permitted, the soil from
borrow areas shall first be freed of all vegetation and
other deleterious matter and placed on the prepared
Subgrade. The soil shall then be pulverised by means
of crow-bars, pick axes or other means approved by
the Engineer.
Water in requisite quantities may be
sprinkled on the soil for aiding pulverisation. On the
pulverised soil, the blending material(s) in requisite
quantities shall be spread uniformly and mixed
thoroughly by working with spades or other similar
implements till the whole mass is uniform. After
adjusting the moisture content to be within the limits
mentioned later, the mixed material shall be levelled
up to the required thickness so that it is ready to be
rolled.
402.3.6. Addition of lime: Lime may be

mixed with the prepared material either in slurry
form or dry state at the option of the Contractor with
the approval of the Engineer.
Dry lime shall be prevented from blowing by
adding water to the or other suitable means selected
by the Contractor, with the approval of the Engineer.
The tops of windrowed material may be
flattened or slightly trenched to receive the lime. The
distance to which lime may be spread upon the
prepared material ahead of the mixing operation
shall be determined by the Engineer.
No traffic other than the mixing equipment
shall be allowed to pass over the spread lime until
Page 246 of 1427

after completion of mixing.
Mixing or remixing operations, regardless of
equipment used, shall continue until the material is
free of any white streaks or pockets of lime and the
mixture is uniform.
Non-uniformity of colour reaction, when the
treated material is tested with the standard
phenolphthalein alcohol indicator, will be considered
evidence of inadequate mixing.
402.3.7. Moisture content for

compaction: The moisture content at compaction
checked vide IS :2720 (Part 2) shall neither be less
than the optimum moisture content corresponding
to IS: 2720 (Part 8) nor more than 2 per cent above
it.
402.3.8. Rolling: Immediately after

spreading, grading and levelling of the mixed
material, compaction shall be carried out with
approved equipment preceded by a few passes of
lighter rollers if necessary. Rolling shall commence
at edges and progress towards the centre, except at
superelevated portions where it shall commence at
the inner edge and progress towards outer edge.
During rolling the surface shall be frequently
checked for grade and crossfall (camber) and any
irregularities corrected by loosening the material
and removing/ adding fresh material. Compaction
shall continue until the density achieved is at least 98
per cent of the maximum dry density for the
material determined in accordance with IS: 2720
Page 247 of 1427

(Part 8).
Care shall be taken to see that the compaction
of lime stabilised material is completed within three
hours of its mixing or such shorter period as may be
found necessary in dry weather.
During rolling it shall be ensured that roller
does not bear directly on hardened or partially
hardened treated material previously bid other than
what may be necessary for achieving the specified
compaction at the joint. The final surface shall be
well closed, free from movement under compaction
planes, ridges, cracks or loose material. All loose or
segregated or otherwise defective areas shall be
made good to the full thickness of the layer and
recompacted.
Page 248 of 1427

402.3.9. Curing: The sub-base course shall
be suitably cured for a minimum period of 7 days
after which subsequent pavement courses shall be
laid to- prevent the surface from drying out and
becoming friable. No traffic of any kind shall ply
over the completed sub-base unless permitted by
the Engineer.

of Work

with Section 900.
402.5. Strength
When lime is used for improving the

subgrade, the soil-lime mix shall be tested for its
CBR value. When lime stabilised soil is used in a
sub-base, it shall be tested for unconfined
compressive strength (UCS) at 7 days. In case of
variation from the design CBR/UCS, in situ value
being lower, the pavement design shall be reviewed
based on the actual CBR/UCS values. The extra
pavement thickness needed on account of lower
CBR/UCS value shall be constructed by the
Contractor at his own cost.
402.6. Arrangements of Traffic
Page 249 of 1427

Stabilised soil sub-base shall be measured as

402.8. Rates
The Contract unit rate for lime stabilised soil

sub-base shall be payment in full for carrying out the
all components listed in Clause 401.8 (i) to (v).
403. CEMENT TREATED SOIL SUB-

BASE/BASE
403.1. Scope

compacting a sub-base/base course of soil treated
with cement on prepared subgrade/sub-base, in ac-
cordance with the requirements of these
Specifications and in conformity with the lines,
as directed by the Engineer.
Page 250 of 1427

403.2. Materials
403.2.1. Material to be stabilised: The

material used for cement treatment shall be soil
including sand and gravel, laterite, kankar, brick
aggregate, crushed rock or slag or any combination
of these. For use in a sub-base course, the material
shall have a grading shown in Table 400-4; it shall
have a uniformity coefficient not less than 5, capable
of producing a well closed surface finish. For use in
a base course, the material shall be sufficiently well
graded to ensure a well-closet surface finish and
have a grading within the range given in Table 400-
4. If the material passing 425 micron sieve is plastic,
it shall have a liquid limit not greater than 45 per
cent and a plasticity index not grater than 20 per cent
determined in accordance with 1S:2720 (Part 5). The
physical requirements for the material to be treated
with cement for use in a base course shall be same as
for Grading I Granular Sub-base, Clause 401.2.2.
403.2.2. Cement: Cement for cement

stabilisation shall comply with the requirements of
IS: 269, 455 or 1489.
Table 400-4. GRADING LIMITS OF

MATERIAL I OK STABILISATION WITH
CEMENT
IS Sieve size Percentage by mass passing
Sub-base
Finer than
Page 251 of 1427

53.0 mm 100
37.5 mm 95
19.0 mm 45
9.5 mm 35
4.75 mm 25
600 micron 8
300 micron 5
75 micron 0
403.2.3. Lime: If needed for pre-treatment

of highly clayey soils, Clause 402.2.2. shall apply.
403.2.4. Quantity of cement in stabilised

mix: The quantity of cement to be added as per cent
by weight of the dry soil shall be specified in the
Contract. Also if lime is used as pretreatment for
highly clayey soils, the quantity as per cent by
weight of dry soil shall be specified in the Contract.
The mix design shall be done on the basis of 7-day
unconfined compressive strength (UCS) and/or
durability lest under 12 cycles of wet-dry
conditions. The laboratory strength values shall be at
least 1.5 times the minimum field UCS value
stipulated in the Contract.
403.2.5. Water: The water to be used for

cement stabilisation shall be clean and free from
injurious substances. Potable water shall be
preferred.
Page 252 of 1427

403.3.1.Weather limitations : Stabilisation
shall not be done when the air temperature in the
shade is less than 10°C.
Page 253 of 1427

403.3.2. Degree of pulverisation : For
stabilisation, the soil before addition of stabilizer,
shall be pulverised, where necessary, to the extent
that it passes the requirements as set out in Table
400-5 when tested in accordance with the method
described in Appendix 3.
TABLE 400-5. SOIL PULVERISATION

REQUIREMENTS FOR CEMENT
STABILISATION
IS Sieve designation Minimum per cent
by weight passing the IS
sieve
26.5 mm 100
5.6 mm 80
403.3.3. Clauses 402.3.3 to 402.3.5 shall

apply as regards spreading and mixing the stabiliser
except that cement or lime plus cement as the case
may be shall be used as the stabilising material.
403.3.4. Moisture content for compaction:

The moisture content at compaction checked vide
IS: 2720 (Part 2) shall not be less than the optimum
moisture content corresponding to IS: 2720 (Part 8)
nor more than 2 per cent above it.
403.3.5. Roiling : Clause 402.3.8 shall apply

except that care shall be taken to see that the
compaction of cement stabilised material is
completed within two hours of its mixing or such
shorter period as may be found necessary in dry
Page 254 of 1427

weather.
403.3.6. Curing : The sub-base/base course

shall be suitably cured for 7 days. Subsequent
pavement course shall be laid soon after to prevent
the surface from drying out and becoming friable.
No traffic of any kind shall ply over the
completed sub-base unless permitted by the
Engineer.

of Works

403.5. Strength

with Section 900.
Cement treated soil sub-base /base shall be
tested for the unconfined compressive strength
(UCS) value at 7 days, actually obtained in situ. In
case of variation from the design UCS, in situ value
being on lower side, prior to proceeding with laying
of base/surface course on it, the pavement design
shall be reviewed for actual UCS value. The extra
pavement thickness needed on account of lower
UCS shall be constructed by the Contractor at his
own cost.
Page 255 of 1427


Page 256 of 1427

Stabilised soil sub-base/ base shall be

measured as finished work in position in cubic
metres.
403.8. Rates
The Contract unit rate for cement treated soil

sub-base/base with pretreatment with lime if
required shall be payment in full for carrying out the
all components listed in Clause 401.8 (i) to (v).
404. WATER BOUND MACADAM SUB-

BASE/BASE
404.1. Scope
404.1.1. This work shall consist of clean,

crushed aggregates mechanically interlocked by
rolling and bonding together with screening, binding
material where necessary and water laid on a
properly prepared subgrade/ sub-base/ base or
existing pavement, as the case may be and finished
in accordance with the requirements of these
Specifications and in close conformity with the lines,
grades, cross-sections and thickness as per approved
plans or as directed by the Engineer.
404.1.2. It is, however, not desirable to lay
water bound macadam on an existing thin black
topped surface without providing adequate drainage
Page 257 of 1427

facility for water that would get accumulated at the
interface of existing bituminous surface and water
bound macadam.
404.2. Materials
404.2.1. Coarse aggregates : Coarse

aggregates shall be either crushed or broken stone,
crushed slag, overburnt (Jhama) brick aggregates or
any other naturally occurring aggregates such as
kankar and laterite of suitable quality. Materials
other than crushed or broken stone and crushed slag
shall be used in sub-base courses only. If crushed
gravel/ shingle is used, not less than 90 per cent
by weight of the gravel/ shingle pieces retained on
4.75 mm sieve shall have at least two fractured
faces. The aggregates shall conform to the physical
requirements set forth in Table 400-6. The type and
size range of the aggregate shall be specified in the
Contract or shall be as specified by the Engineer. If
the water absorption value of the coarse aggregate is
greater than 2 per cent, the soundness test shall be
carried out on the material delivered to site as per IS
: 2386 (Part 5).
404.2.2. Crushed or broken stone: The

crushed or broken stone shall be hard, durable and
free from excess flat, elongated, soft and
disintegrated particles, dirt and other deleterious
material.
Page 258 of 1427

TABLE 400-6. PHYSICAL
REQUIREMENTS OF
COARSE AGGREGATES
FOR WATER BOUND
MACADAM FOR SUB-
BASE/BASE COURSES
Test Test Method Requ
1 * Los Angeles IS:2386 40 pe

Abrasion value (Part-4)
Or
* Aggregate IS:2386 30 pe
Impact value (Part-4) or
IS:5640**
2 Combined
Flakiness and IS:2386 30 pe
Elongation (Part-1)
Indices (Total)
***
* Aggregate may satisfy requirements of either
of the two tests.
** Aggregates like brick metal, kankar, laterite
etc. which get softened in presence of water
shall be tested for Impact value under wet
conditions in accordance with IS: 5640.
*** The requirement of flakiness index and
elongation index shall be enforced only in the
case of crushed broken stone and crushed
slag.
404.2.3. Crushed slag : Crushed slag shall
Page 259 of 1427

be made from air-cooled blast furnace slag. It shall
be of angular shape, reasonably uniform in quality
and density and generally free from thin, elongated
and soft pieces, dirt or other deleterious materials.
The weight of crushed slag shall not be less than
11.2 kN per m3 and the percentage of glossy material
shall not be more than 20. It should also comply with
the following requirements:
(i) Chemical stability :
To comply with requirement of
a
p
p
e
n
d
i
x
o
f
B
S
:
1
0
4
7
(ii) Sulphur content :
Maximum 2 per cent
(iii) Water absorption :
Page 260 of 1427

Maximum 10 per cent
404.2.4. Overburnt (Jhama) brick

aggregates : Jhama brick aggregates shall be
made from overburnt bricks or brick bats and be free
from dust and other objectionable and deleterious
materials.
404.2.5. Grading requirement of coarse

aggregates : The coarse aggregates shall
conform to one of the Gradings given in Table
400-7 as specified, provided, however, the use of
Grading No.1 shall be restricted to sub-base courses
only.
Page 261 of 1427

TABLE 400-7. GRADING
REQUIRMENTS OF COARSE AGGREGATES
Grading Size Range IS Sieve Designation P

No. p
1. 90 mm to 45 mm 125 mm
90 mm
63 mm
45 mm
22.4 mm
2. 63 mm to 45 mm 90 mm
63 mm
53 mm
45 mm
22.4 mm
3. 53 mm lo 22.4 mm 63 mm
53 mm
45 mm
22.4 mm
11.2 mm
Note : The compacted thickness for a layer with

Grading 1 shall be100 mm while for layer with other
Gradings i.e. 2 & 3, it shall be 75 mm.
404.2.6. Screenings: Screenings to fill voids

in the coarse aggregate shall generally consist of the
same material as the coarse aggregate. However,
where permitted, predominantly non-plastic material
such as moorum or gravel (other than rounded river
borne material) may be used for this purpose
Page 262 of 1427

provided liquid limit and plasticity index of such
material are below 20 and 6 respectively and fraction
passing 75 micron sieve does not exceed 10 per cent.
Screenings shall conform to the grading set
forth in Table 400-8. The consolidated details of
quantity of screenings required for various grades of
stone aggregates are given in Table 400-9. The table
also gives the quantities of materials (loose) required
for 10 m2 for sub-base/base compacted thickness of
100/75 mm.
The use of screenings shall be omitted in the
case of soft aggregates such as brick metal, kankar,
laterites, etc. as they arc likely to get crushed to a
certain extent under rollers.
TABLE 400-8. GRADING FOR
SCREENINGS
Grading Size of IS Sieve Designation Per c

Classification Screenings passi
A 13.2 mm 13.2 mm
11.2 mm 95
5.6 mm 1
180 micron
B 11.2 mm 11.2 mm
5.6 mm 90
180 micron 1
Page 263 of 1427

TABLE 400-9. APPROXIMATE
QUANTITIES OF COARSE
AGGREGATES AND
SCREENINGS REQUIRED
FOR 100/75 MM
COMPACTED THICK-
NESS OF WATER BOUND
MACADAM (WBM) SLB-
BASE/BASK COURSE
FOR 10M2 AREA
Classifica Size Compacted Lose Screenings

tion Range thickness Qty. Stone Screening
Grading For. WHM

Classifica Sub-base/
tion base course
& Size (Loose
quantity)
Grading 1 90 mm to 100 mm 1.21 to Type A 0.27 to
45 mm 1.43m3 13.2mm 0.30 m3
Grading 2 63 mm to 75 mm 0.91 to Type A 0.12 to
45mm 1.07 m3 13.2mm 0.15 m3
-do- -do- -do- -do- Type B 0.20 to
11.2mm 0.22 m3
Grading 3 53mm to 75 mm -do- -do- 0.18 to
22.4mm 0.21 m3
404.2.7. Binding material : Binding material

to be used for water bound macadam as a filler
Page 264 of 1427

material meant for preventing ravelling, shall
comprise of a suitable material approved by the
Engineer having a Plasticity Index(PI) value of less
than 6 as determined in accordance with IS: 2720
(Part-5).
The quantity of binding material where it is
to be used, will depend on the type of screenings.
Generally, the quantity required for 75 mm
compacted thickness of water bound macadam will
be 0.06-009 m3/10m2 and 0.08-0.10m3/10m2 for 100
mm compacted thickness.
The above mentioned quantities should be
taken as a guide only, for estimation of quantities for
construction etc.
Application of binding materials may not be
necessary when the screenings used are of crushable
type such as moorum or gravel.
404.3.1. Preparation of base: The surface of

the subgrade/ sub-base/base to receive the water
bound macadam course shall be prepared to the
specified lines and crossfall (camber) and made free
of dust and other extraneous material. Any ruts or
soft yielding places shall be corrected in an approved
manner and rolled until firm surface is obtained if
necessary by sprinkling water. Any sub-
base/base/surface irregularities, where predominant,
shall be made good by providing appropriate type of
profile corrective course (levelling course) to Clause
501 of these Specifications.
Page 265 of 1427

As far as possible, laying water bound
macadam course over an existing thick bituminous
layer may be avoided since it will cause problems of
internal drainage of the pavement at the interface of
two courses. It is desirable to completely pick out the
Page 266 of 1427

existing thin bituminous wearing course where water
bound macadam is proposed to be laid over it.
However, where the intensity of rain is low and the
interface drainage facility is efficient, water bound
macadam can be laid over the existing thin
bituminous surface by cutting 50 mm x 50 mm
furrows at an angle of 45 degrees to the centre line
of the pavement at one metre intervals in the existing
road. The directions and depth of furrows shall be
such that they provide adequate bondage and also
serve to drain water to the existing granular base
course beneath the existing thin bituminous surface.
404.3.2. Inverted choke : If water bound

macadam is to be laid directly over the subgrade,
without any other intervening pavement course, a
25 mm course of screenings (Grading B) or
coarse sand shall be spread on the prepared
subgrade before application of the aggregates .is
taken up. In case of a fine sand or silty or clayey
subgrade, it is advisable to lay 100 mm insulating
layer of screening or coarse sand on top of Fine
grained soil, the gradation of which will depend
upon whether it is intended to act as a drainage layer
as well. As a preferred alternative to inverted choke,
appropriate geosynthetics performing functions of
separation and drainage may be used over the
prepared subgrade as directed by the Engineer.
Section 700 shall be applicable for use of
geosynthetics.
404.3.3. Spreading coarse aggregates : The
Page 267 of 1427

coarse aggregates shall be spread uniformly and
evenly upon the prepared subgrade/sub-base/ base
to proper profile by using templates placed across
the road about 6 m apart, in such quantities that the
thickness of each compacted layer is not more than
100 mm for Grading 1 and 75 mm for Grading 1 and
3, as specified in Clause 404.2.5. Wherever possible,
approved mechanical devices such as aggregate
spreader shall be used to spread the aggregates
uniformly so as to minimise the need for manual
rectification afterwards. Aggregates placed at
locations which are inaccessible to the spreading
equipment, may be spread in one or more layers by
any approved means so as to achieve the specified
results.
The spreading shall be done from stockpiles
along the side of the roadway or directly from
vehicles. No segregation of large or fine aggregates
shall be allowed and the coarse aggregate as spread
shall be of uniform gradation with no pockets of fine
material.
The surface of the aggregates spread shall be
carefully checked with templates and all high or low
spots remedied by removing or adding aggregates as
may be required. The surface shall be checked
frequently with a straight edge while spreading and
rolling so as to ensure a finished surface as per
approved drawings.
The coarse aggregates shall not normally be
spread more than 3 days in advance of the
subsequent construction operations.
Page 268 of 1427

404.3.4. Rolling: Immediately following the
spreading of the coarse aggregate, rolling shall be
started with three wheeled power rollers of 80 to
100 kN capacity or tandem or vibratory rollers of 80
to 100 kN static weight. The type of roller to be
used shall be approved by the Engineer based on
trial run.
Except on superelevated portions where the
rolling shall proceed from inner edge to the outer,
rolling shall begin from the edges gradually
progressing towards the centre. First the edge/edges
shall be compacted with roller running forward and
backward. The roller shall then move inward parallel
to the centre line of the road, in successive passes
uniformly lapping preceding tracks by at least one
half width.
Page 269 of 1427

Rolling shall be discontinued when the
aggregates arc partially compacted with sufficient
void space in them to permit application of
screenings. However, where screenings are not to be
applied, as in the case of crushed aggregates like
brick metal, laterite and kankar, compaction shall be
continued until the aggregates are thoroughly keyed.
During rolling, slight sprinkling of water may be
done, if necessary. Rolling shall not be done when
the subgrade is soft or yielding or when it causes a
wave-like motion in the subgrade or sub-base course.
The rolled surface shall be checked
transversely and longitudinally, with templates and
any irregularities corrected by loosening the surface,
adding or removing necessary amount of aggregates
and re-rolling until the entire surface conforms to
desired crossfall (camber) and grade. In no case shall
the use of screenings the permitted to make up
depressions.
Material which gets crushed excessively
during compaction or becomes segregated shall be
removed and replaced with suitable aggregates.
It shall be ensured that shoulders are built up
simultaneously along with water bound macadam
courses as per Clause 407.4.1.
404.3.5. Application of screenings: After

the coarse aggregate has been rolled to Clause
404.3.4, screenings to completely fill the interstices
shall be applied gradually over the surface. These
shall not be damp or wet at the time of application.
Dry rolling shall be done while the screenings are
Page 270 of 1427

being spread so that vibrations of the roller cause
them to settle into the voids of the coarse aggregate.
The screenings shall not be dumped in piles but be
spread uniformly in successive thin layers either by
the spreading motions of hand shovels or by
mechanical spreaders, or directly from tipper with
suitable grit spreading arrangement. Tipper operating
for spreading the screenings shall be so driven as not
to disturb die coarse aggregate.
The screenings shall be applied at a slow and
uniform rate (in three or more applications) so as to
ensure filling of all voids. This shall be accompanied
by dry rolling and brooming with mechanical
brooms, hand-brooms or both. In no case shall the
screenings be applied so fast and thick as to form
cakes or ridges on the surface in such a manner as
would prevent filling of voids or prevent the direct
bearing of the roller on the coarse aggregate. These
operations shall continue until no more screenings
can be forced into the voids of the coarse aggregate.
The spreading, rolling, and brooming of
screenings shall be carried out in only such lengths
of (he road which could be completed within one
day’s operation.
404.3.6. Sprinkling of water and grouting :

After the screenings have been applied, the surface
shall be copiously sprinkled with water, swept and
rolled. Hand brooms shall be used to sweep
the wet screenings into voids and to distribute them
evenly. The sprinkling, sweeping and rolling
operation shall be continued, with additional
Page 271 of 1427

screenings applied as necessary until the coarse
aggregate has beer thoroughly keyed, well-bonded
and firmly set in its full depth and a grout has
been formed of screenings. Care shall be taken to sec
that the base or subgrade does not get damaged due
to the addition of excessive quantities of water
during construction.
In case of lime treated soil sub-base,
construction of water bound macadam on top of it
can cause excessive water to flow down to the lime
treated sub-base before it has picked up enough
strength (is still “green”) and thus cause damage to
the sub-base layer. The laying of water bound
macadam layer in such cases shall be done after the
sub-base attains adequate strength, as directed by the
Engineer.
Page 272 of 1427

404.3.7. Application of binding material:
After the application of screenings in accordance
with Clauses 404.3.5 and 404.3.6. the binding
material where it is required to be used
(Clause 404.2.7) shall be applied successively in
two or more thin layers at a slow and uniform
rate. After each application, the surface shall be
copiously sprinkled with water, the resulting slurry
swept in with hand brooms, or mechanical brooms
to fill the voids properly, and rolled during which
water shall be applied to the wheels of the rollers if
necessary to wash down the binding material
sticking to them. These operations shall continue
until the resulting slurry after filling of voids, form a
wave ahead of the wheels of the moving roller.
404.3.8. Setting and drying: After the final

compaction of water bound macadam course, the
pavement shall be allowed to dry overnight. Next
morning hungry spots shall be filled with screenings
or binding material as directed, lightly sprinkled with
water if necessary and rolled. No traffic shall be
allowed on the road until the macadam has set. The
Engineer shall have the discretion to stop hauling
traffic from using the completed water bound
macadam course, if in his opinion it would cause
excessive damage to the surface.
The compacted water bound macadam course
should be allowed to completely dry and set before
the next pavement course is laid over it.
Page 273 of 1427

of Work
404.4.1. The surface finish of construction

shall conform to the requirements of Clause 902.
404.4.2. Control on the quality of materials

and works shall be exercised by the Engineer in
accordance with Section 900.
404.4.3. The water bound macadam work

shall not be carried out when the atmospheric
temperature is less than 0°C in the shade.
404.4.4. Reconstruction of defective

macadam: The finished surface of water bound.
macadam shall conform to the tolerance of surface
regularity as prescribed in Clause 902. However,
where the surface irregularity of the course exceeds
the tolerances or where the course is otherwise
defective due to subgrade soil mixing with the
aggregates, the course to its full thickness shall be
scarified over the affected area, reshaped with
added material or removed and replaced with
fresh material as applicable and recompacted. In no
case shall depressions be filled up with screenings or
binding material.
404.5. Arrangement for Traffic
During the period of construction, the

arrangement of traffic shall be done as per Clause
112.
Page 274 of 1427

404.6. Measurements for payment
Water bound macadam shall be measured as

Page 275 of 1427

404.7. Rate
The Contract unit rate for water bound

macadam sub-base/base course shall be payable in
full for carrying out the required operations
including full compensation for all components
listed in Clause 401.8 (i) to (v) including
arrangement of water used in the work as approved
by the Engineer.
405. CRUSHED CEMENT CONCRETE SUB-

BASE/BASE
405.1. Scope
This work shall consist of breaking and

crushing the damaged cement concrete slabs and
recompacting the same as sub-base/base course in
one or more layers. Where specified, it shall also
include treating the surface of the top layer with a
penetration coat of bitumen. The work shall be
performed on such widths and lengths as may be
specified, in accordance with the requirements of
these Specifications and in conformity with the lines,
as otherwise directed by the Engineer.
405.2. Materials
405.2.1. Coarse aggregate : Coarse

aggregate for this work shall be broken cement
concrete slabs crushed to a size not exceeding 75
Page 276 of 1427

mm and as far as possible, conforming to one of the
grading given in Table 400-7.
405.2.2. Key aggregate : Key aggregate for

the penetration coal shall consist of crushed stone,
crushed gravel, shingle or other stones. It shall be
clean, strong, durable, of fairly cubical shape and
free of disintegrated pieces, organic or other
deleterious matter and adherent coatings. The
aggregate shall be hydrophobic and of low porosity.
The aggregate shall be of 11.2 mm size
defined as 100 per cent passing through 13.2 mm
sieve and retained on 5.6 mm sieve and shall satisfy
the physical requirements set forth in Table 500-3.
405.2.3. Binder: Binder for the penetration

coal for the top layer shall be bitumen of a suitable
grade, as directed by the Engineer and satisfying the
requirements of IS: 73,217 or 454, as applicable or
any approved cutback or emulsion, satisfying the
requirements of IS:8887.
405.3.1. General: Crushed cement concrete

sub-base/base course may be constructed in one or
two layers, depending upon the thickness of the
concrete slabs dismantled and crushed. The
thickness of each layer shall, however, not exceed
100 mm m case of sub-base and 75 mm in case of
base course.
The course shall be constructed as water
Page 277 of 1427

bound macadam to Clause 404, using crushed
cement concrete as coarse aggregate except that no
screenings or binding material need be applied.
Where specified, the top layer shall be treated with a
penetration coat of binder described in Clause
405.3.2.
Page 278 of 1427

405.3.2. Application of penetration coat
over the top layer: Before the application of the
penetration coat, the surface shall be cleaned of dust,
dirt and other foreign matter, using mechanical
broom or any other equipment specified by the
Engineer. Dust removed in the process shall be
blown off with the help of compressed air.
The binder shall be heated to the temperature
appropriate to the grade of bitumen used and sprayed
on the dry surface in a uniform manner at the rate of
25 kg per 10 m: area in terms of the residual bitumen
with the help of cither self-propelled or towed
bitumen pressure sprayer with self-healing
arrangement and spray nozzle capable of spraying
bitumen at specified rates and temperatures so as to
provide a uniform, unbroken spread of bitumen.
Excessive deposits of binder caused by stopping or
starting of the sprayer or through leakage or any
other reason shall be suitably corrected.
Immediately after the application of binder,
the key aggregates, in a clean and dry state shall be
spread uniformly on the surface at the rate of 0.13
m3 per 10 m2 area, preferably by means of a
mechanical gritter, capable of spreading aggregate
uniformly at specified rates or otherwise manually
with the approval of the Engineer, so as to cover the
surface completely. Immediately after the
application of the key aggregates, the entire surface
shall be roiled to Clause 506.3.8.

Control of Works
Page 279 of 1427

Control on the quality of material and works
with Section 900.

112.
Breaking the existing cement concrete

pavement slabs, crushing and recompacting the slab
material as sub-base/base course shall be measured
as a single item in terms of the volume of sub-
base/base laid in position in cubic metres.
Penetration coat shall be measured as
405.7. Rates
405.7.1. The Contract unit rate for crushed

cement concrete sub-base/base course shall be
operations including full compensation for:
(i) making arrangements for traffic to
treatment to verges/shoulders and
Page 280 of 1427

(ii) breaking the cement concrete slabs,
crushing, sieving and recompacting
the slab material as sub-
base/base course;
incidentals to complete the work
to the Specifications; and
(iv) carrying out the work in part
widths of road where directed.
Page 281 of 1427

penetration coat shall be payment in full for
carrying out the required operations including
full compensation for all components listed in
Clause 504.8.
406. WET MIX MACADAM SUB-

BASE/BASE
406.1. Scope

compacting clean, crushed, graded aggregate and
granular material, premixed with water, to a dense
mass on a prepared subgrade/sub-base/base or
existing pavement as the case may be in accordance
with the requirements of these Specifications. The
material shall be laid in one or more layers as
necessary to lines, grades and cross-sections shown
on the approved drawings or as directed by the
Engineer.
The thickness of a single compacted Wet
Mix Macadam layer shall not be less than 75 mm.
When vibrating or other approved types of
compacting equipment arc, used, the compacted
depth of a single layer of the sub-base course may be
increased to 200 mm upon approval of the Engineer.
406.2. Materials
406.2.1. Aggregates
Page 282 of 1427

406.2.1.1. Physical requirements: Coarse
aggregates shall be crushed stone. If crushed
gravel/shingle is used, not less than 90 per cent by
weight of the gravel/shingle pieces retained on 4.75
mm sieve shall have at least two fractured faces. The
aggregates shall conform to the physical
requirements set forth in Table 400-10 below.

REQUIRMENTS OF COARSE AGGREGATES
FOR WET MIX
MACADAM FOR SUB-
BASE/BASE COURSES
Test Test Method Requ
1 * Los Angeles IS:2386 40 pe

Abrasion value (Part-4)
Or
* Aggregate IS:2386 30 pe
IS:5640
2 Combined
Flakiness and IS:2386 30 pe
Elongation (Part-1)
Indices (Total)
of the two tests.
** To determine this combined proportion, the
flaky stone from a representative sample
should first be separated out. Flakiness index
is weight of flaky stone metal divided by
weight of stone sample. Only the elongated
Page 283 of 1427

particles be separated out from the remaining
(non-flaky) stone metal. Elongation index is
weight of elongated particles divided by total
non-flaky particles. The value of flakiness
index and elongation index so found are
added up.
Page 284 of 1427

If the water absorption value of the coarse
aggregate is greater than 2 per cent, the soundness
test shall be carried out on the material delivered to
site as per IS:2386(Part-5).
406.2.1.2. Grading requirements : The

aggregates shall conform to the grading given in
Table 400-11.

REQUIREMENTS OF AGGREGATES FOR
WET MIX MACADAM
IS Sieve Designation Per cent by weight
passing the IS sieve
53.00 mm 100
45.00 mm 95-100
26.50 mm --
22.10 mm 60-80
11.20 mm 40-60
4.75 mm 25-40
2.36 mm 15-30
600.00 micron 8-22
75.00 micron 0-8
Materials finer than 425 micron shall have
Plasticity Index (PI) not exceeding 6.
The final gradation approved within these
limits shall be well graded from coarse to fine and
shall not vary from the low limit on one sieve to the
high limit on the adjacent sieve or vice versa.
Page 285 of 1427

406.3.1. Preparation of base : Clause
404.3.1. shall apply.
406.3.2. Provision of lateral confinement of

aggregates: While constructing wet mix macadam,
arrangement shall be made for the lateral
confinement of wet mix. This shall be done by
laying materials in adjoining shoulders along with
that of wet mix macadam layer and following the
sequence of operations described in Clause 407.4.1.
406.3.3. Preparation of mix: Wet Mix

Macadam shall be prepared in an approved mixing
plant of suitable capacity having provision for
controlled, addition of water and forced/positive
mixing arrangement like pugmill or pan type mixer
of concrete batching plant. For small quantity of
wet mix work, the Engineer may permit the mixing
to be done in concrete mixers.
Optimum moisture for mixing shall be
determined in accordance with IS:2720 (Part-8) after
replacing the aggregate fraction retained on 22.4 mm
sieve with material of 4.75 mm to 22.4 mm size.
While adding water, due allowance should be made
for evaporation losses. However, at the time of
compaction, water in the wet mix should not vary
from the optimum value by more than agreed limits.
The mixed material should be uniformly wet and no
segregation should be permitted.
406.3.4. Spreading of mix : Immediately

after mixing, the aggregates shall be spread
Page 286 of 1427

uniformly and evenly upon the prepared
subgrade/sub- base/bass in required quantities. In no
case should these be dumped in heaps directly on the
area where these are to be laid nor shall their hauling
over a partly completed stretch be permitted.
The mix may be spread either by a paver
finisher or motor grader. For portions where
mechanical means cannot be used, manual means as
approved by the Engineer
Page 287 of 1427

shall be used. The motor grader, shall be capable of
spreading the material uniformly all over the surface.
Its blade shall have hydraulic control suitable for
initial adjustments and maintaining the same so as to
achieve the specified slope and grade.
The paver finisher shall be self-propelled,
having the following features:
(i) Loading hoppers and suitable
distribution mechanism
(ii) The screed shall have tamping and
vibrating arrangement for initial
compaction to the layer as it is spread
without rutting or otherwise marring
the surface profile.
(iii) The paver shall be equipped with
necessary control mechanism so as to
ensure that the finished surface is free
from surface blemishes.
The surface of the aggregate shall be
carefully checked with templates and all high or low
spots remedied by removing or adding aggregate
may be required. The layer may be tested by depth
blocks during construction. No segregation of larger
and fine panicles should be allowed. The aggregates
as spread should be of uniform gradation with no
pockets of fine materials.
406.3.5. Compaction: After the mix has seen

laid to the required thickness, grade and
crossfall/camber the same shall be uniformly com-
pacted, to the full depth with suitable roller. If the
thickness of single compacted layer does not exceed
Page 288 of 1427

100 mm, a smooth wheel roller of 80 to 100 kN
weight may be used. For a compacted single layer
upto 200 mm, the compaction shall be done with the
help of vibratory roller of minimum static weight of
80 to 100 kN or equivalent capacity roller. The speed
of the roller shall not exceed 5 km/h.
In portions having unidirectional cross
fall/superelevation, rolling shall commence from the
lower edge and progress gradually towards the upper
edge. Thereafter, roller should progress parallel to
the centre line of the road, uniformly over-lapping
each preceding track by at least one-third width until
the entire surface has been rolled. Alternate trips of
the roller shall be terminated in stops at least 1 m
away from any preceding stop.
In portions in camber, rolling should begin at
the edge with the roller running forward and
backward until the edges have been firmly
compacted. The roller shall then progress gradually
towards the centre parallel to the centre line of the
road uniformly overlapping each of the preceding
track by at least one-third width until the entire
surface has been rolled.
Any displacement occurring as a result of
reversing of the direction of a roller or from any
other cause shall be corrected at once as specified
and/or removed and made good.
Along forms, kerbs, walls or other places not
accessible to the roller, the mixture shall be
thoroughly compacted with mechanical tampers or a
plate compactor. Skin patching of an area without
scarifying the surface to permit proper bonding of
Page 289 of 1427

the added material shall not be permitted.
Rolling should not be done when the
subgrade is soft or yielding or when it causes a
wave-like motion in the sub-base/base course or
subgrade. If irregularities develop during rolling
which exceed 12 mm when tested with a 3 metre
straight edge, the surface should be loosened and
premixed material added or removed as required
before rolling again so as to achieve a uniform
surface conforming to the desired grade and
crossfall. In no case should the use of unmixed
material be permitted to make up the depressions.
Page 290 of 1427

Rolling shall be continued till the density
achieved is at least 98 per cent of the maximum dry
density for the material as determined by the method
outlined in IS: 2720 (Part-8)
After completion, the surface of any finished
layer shall be well-closed, free from movement
under compaction equipment or any compaction
planes, ridges, cracks and loose material. All loose,
segregated or otherwise defective areas shall be
made good to the full thickness of the layer and
recompacted.
406.3.6. Setting and drying: After final

compaction of wet mix macadam course, the road
shall be allowed to dry for 24 hours.
406.4. Opening to Traffic
Preferably no vehicular traffic of any kind

should be allowed on the finished wet mix macadam
surface till it has dried and the wearing course laid.

of Work
406.5.1. Surface evenness : The surface

finish of construction shall conform to the
406.5.2. Quality control : Control or, the

quality of materials and works shall be exercised
by the Engineer in accordance with Section 900.
Page 291 of 1427

406.6. Rectification of Surface
Irregularity
Where the surface irregularity of the wet mix

macadam course exceeds the permissible tolerances
or where the course is otherwise defective due to
subgrade soil getting mixed with the aggregates, the
full thickness of the layer shall be scarified over the
affected area, reshaped with added premixed
material or removed and replaced with fresh
premixed material as applicable and recompacted in
accordance with Clause 406.3. The area treated in
the aforesaid manner shall not be less than 5 m long
and 2 m wide. In no case shall depressions be filled
up with unmixed and ungraded material or fines.
406.7. Arrangement for Traffic

112.
Wet mix macadam shall be measured as

406.9. Rates
The Contract unit rate for wet mix macadam

shall be .payment in full for carrying out the required
Page 292 of 1427

components listed in Clause 401.8.
Page 293 of 1427

407. SHOULDERS, ISLANDS AND
MEDIAN
407.1. Scope
The work shall consist of constructing

shoulder (hard/paved/earthen with brick or stone
block edging) on either side of the pavement, median
in the road dividing the carriageway into separate
lanes and islands for channelising the traffic at
junctions in accordance with the requirements of
these Specifications and in conformity with the lines,
407.2. Materials
Shoulder on either side of the road may be of

selected earth/ granular material/ paved conforming
to the requirements of Clause 305/401 and the
median may be of selected earth conforming to the
Median/Traffic islands shall be raised and
kerbed at the perimeter and the enclosed area filled
with earth and suitably covered with grass
turf/shrubs as per Clause 307 and/or paved as per
Clause 409.3.4 or 409.3.5.
Paved shoulders shall consist of sub-base,
base and surfacing courses, as shown in the drawings
and materials for the same shall conform to relevant
Specifications of the corresponding items. Where
paved or hard shoulders arc not provided, the
Page 294 of 1427

pavement shall be provided with brick/stone block
edgings as shown in the drawings. The bricks shall
conform to Clause 1003 of these Specifications.
Stone blocks shall conform to Clause 1004 of these
Specifications and shall be of size 225 mm x 110
mm x 75 mm.
407.3. Size of Shoulders/Median/Islands
Shoulder (earthen/hard/paved)/median/traffic
island dimensions shall be as shown on the drawings
or as directed by the Engineer.
407.4.1. Shoulder: The sequence of

operations shall be such that e construction of
paved shoulder is done in layers each matching the
thickness of adjoining pavement layer. Only after a
layer of pavement and corresponding layers in paved
and earth shoulder portion have been laid and
compacted, the construction of next layer of
pavement and shoulder shall be taken up.
Where the materials in adjacent layers are
different, these shall be laid together and the
pavement layer shall be compacted first. The
corresponding layer in paved shoulder portion shall
be compacted thereafter, which shall be followed by
compaction of earth shoulder layer. The adjacent
layers having same material shall be laid and
compacted together.
In all cases where paved shoulders have to be
Page 295 of 1427

provided along Side of existing carriageway, the
existing shoulders shall be excavated in full width
and to the required depth as per Clause 301.3.7.
Under no circumstances, box cutting shall be done
for construction of shoulders.
Compaction requirement of earthen shoulder
shall be as per Table 300-2. In the case of
bituminous courses, work on shoulder (earthen/
hard/paved), shall start only after the pavement
course has been laid and compacted.
Page 296 of 1427

During all stages of shoulder
(earthen/hard/paved) construction, the required
crossfall shall be maintained to drain off surface
water.
Regardless of the method of laying, all
shoulder construction material shall be placed
directly on the shoulder. Any spilled material
dragged on to the pavement surface shall be
immediately removed, without damage to the-
pavement, and the area so affected thoroughly
cleaned.
407.4.2. Median and Islands : Median and

Islands shall be constructed in a manner similar to
shoulder up to the road level. Thereafter the median
and islands, if raised, shall be raised at least 300
mm by using kerb stones of approved material and
dimensions and suitably finished and painted as
directed by the Engineer. If not raised, the median
and islands shall be differentiated from the shoulder/
pavement as the case may be, as directed by the
Engineer. The confined area of the median and
islands shall be filled with local earth or granular
material or any other approved material and
compacted by plate compactor/power rammer. The
confined area after filling with earth shall be turfed
with grass or planted with shrubs and in case of
granular fill it can be finished with tiles/slabs as
407.4.3. Brick/stone block edging: The

bricks/stone blocks shall be laid on edge, with the
Page 297 of 1427

length parallel to the transverse direction of the road.
They shall be laid on a bed of 25 mm sand, set
carefully rolled into position by a light roller and
made flush with the finished level of the pavement.

of Works

conform to the requirements of Clause 902. Control
on the quality of materials and works shall be
exercised by the Engineer in accordance with
Section 900.
Shoulder (earthen/hard/paved), island and

median construction shall be measured as finished
work in position as below:
(i) For excavation in cu. m.
(ii) For earthwork/granular fill in cu. m.
(iii) For sub-base, base, surfacing
courses in units as for respective
items.
(iv) For kerb in running metres.
(v) For turfing and tile/slab finish in
sq.m.
(vi) For brick/stone block edging in sq m.
407.7. Rate
The Contract unit rate for shoulder
Page 298 of 1427

(hard/paved/earthen with brick or stone block
edging), island and median construction shall be
components listed in Clause 401.8 (i) to (v) as
applicable. The rate for brick/stone block edging
shall include the cost of sand cushion.
Page 299 of 1427

408. CEMENT CONCRETE KERB AND KERB
WITH CHANNEL
408.1. Scope
This work shall consist of constructing

cement concrete kerbs and kerbs with channel in the
central median and/or along the footpaths or
separators in conformity with the lines, levels and
dimensions as specified in the drawings.
408.2. Materials
Kerbs and kerb with channel shall be

provided in cement concrete of Grade M20 in
accordance with Section 1700 of these
Specifications.
408.3. Type of Construction
These shall be cast-in-situ construction with

suitable kerb casting machine in all situations except
at locations where continuous casting with
equipment is not practicable. In those situations,
precast concrete blocks shall be used.
408.4. Equipment
A continuous kerb casting equipment of

adequate capacity and controls, capable of laying the
kerbs in required cross-sections and producing a
well-compacted mass of concrete free of voids and
Page 300 of 1427

honeycombs, shall be used.
408.5.1. Kerb shall be laid on firm

foundation of minimum 150 mm thickness of cement
concrete of M 10 grade cast in-situ or on extended
width of pavement. The foundation shall have a
projection of 50 mm beyond the kerb stone. Before
laying the foundation of lean concrete, the base shall
be levelled and slightly watered to make it damp.
408.5.2. In the median portions in the straight

reaches, the kerb shall be cast in continuous lengths.
In the portions where footpath is provided and/or the
slope of the carriageway is towards median (as in
case of superelevated portions), there shall be
sufficient gap/recess left in the kerb to facilitate
drainage openings.
408.5.3. After laying the kerbs and just prior

to hardening of the concrete, saw cut grooves shall
be provided at 5 m intervals or as specified by the
Engineer.
408.5.4. Kerbs on the drainage ends such as

along the footpath or the median in superelevated
portions, shall be cast with monolithic concrete
channels as indicated in drawings. The slope of the
channel towards drainage pipes shall be ensured for
efficient drainage of the road surface.
Page 301 of 1427

408.5.5. Vertical and horizontal tolerances
with respect to true line and level shall be ± 6 mm.
Page 302 of 1427

Cement concrete kerb/kerb with channel

shall be measured in linear metre for the complete
item of work.
Foundation of kerb, where separately
provided shall be measured in linear metre for
complete item of work.
408.7. Rates
The Contract unit rates for cement concrete

kerb/kerb with enamel and foundation for kerb shall
be payment in full compensation for furnishing all
materials, labour, tools, equipment for construction
and other incidental cost necessary to complete the
work.
409. FOOTPATHS AND SEPARATORS
409.1. Scope
The work shall consist of constructing

footpaths and/or separators at locations as specified
in the drawings or as directed by the Engineer.
. The lines, levels and dimensions shall be as
per the drawings. The scope of the work shall
include provision of all drainage arrangements as
shown in the drawings or as directed.
409.2. Materials
Page 303 of 1427

The footpaths and separators shall be
constructed with any of the following types:
(a) Cast-in-situ cement concrete of Grade
M20 as per Section 1700 of the
Specifications.
(b) Precast cement concrete block/tiles of
Grade M20 as per Section 1700 of
the Specifications The minimum
thickness of the cement concrete
block/tile shall be 23 mm and
minimum size shall be 300 mm x
300 mm.
(c) Natural stone slab cut and dressed
from stone of good and sound quality,
uniform in texture, free from defects
and at least equal to a sample
submitted by the Contractor and
approved by the Engineer. The
minimum thickness of the natural
stone dab shall be 25 mm and
minimum size shall be 300 mm x 300
mm.
409.3.1. Drainage pipes below the footpath

originating from the kerbs shall be first laid in the
required slope and connected to the
drains/sumps/storm water drain/drainage chutes as
per provisions of the drawings, or as specified.
409.3.2. Portion on back side of kerbs shall
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be filled and compacted with granular, sub-base
material as per Clause 401 of the Specifications in
specified thickness.
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409.3.3. The base shall be prepared and
finished to the required lines, levels and dimensions
as indicated in the drawings with the following :-
(a) Minimum 150 mm thick, compacted

granular sub-base material as per
Clause 401 of the Specifications.
(b) Minimum 25 mm thick cement
concrete of Grade M 15.
Over the prepared base, precast concrete
blocks/tiles/natural stone slabs and/or cast-in-situ
slab shall be set/laid as described in Clauses 409.3.4
and 409.3.5.
409.3.4. Precast cement concrete

blocks/tiles/natural stone slab:
The blocks/tiles/slabs shall be set on a layer of
average 12 mm thick cement-sand mortar (1:3) laid
on prepared base in such a way that there is no
rocking. The gaps between the blocks/tiles/slabs
shall not be more than 12 mm and I be filled with
cement-sand mortar (1:3).
409.3.5. Cast-in-situ cement concrete: The
minimum thickness of the cement concrete shall be
25 mm and it shall be cast on the prepared base in
panels of specified size in a staggered manner.
Construction joints shall be provided as per Section
1700 of the Specifications.
Footpaths and separators shall be measured,
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in sq.metre between inside
409.5. Rates
Contract unit rates shall be inclusive of full

compensation of all labour, materials, tools,
equipment and incidentals to construction of
footpaths. Cost providing pipes and arrangement for
their discharge into appropriate drainage channels
shall be incidental to the construction of footpaths.
410. CRUSHER-RUN MACADAM BASE
410.1. Scope
This work shall consist of furnishing, placing

and compacting crushed 5 aggregate sub-base and
base courses constructed in accordance with the
requirements set forth in this Specification and in
conformity with the lines, grades, thicknesses and
cross-sections shown on the plans or as directed by
Engineer.
410.2. Materials
The material to be used for the work shall be

crushed rock. If crashed gravel/shingle is used, not
less than 90 per cent by weight of the gravel/shingle
retained on 4.75 mm sieve shall have at least two
fractured faces. It shall be free from any organic
matter and other deleterious substances and shall be
of such nature that it can be compacted readily under
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watering and rolling to form a firm, stable base. The
aggregate shall conform to the grading and quality
requirements shown in Tables 400-12 and 400-13.
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At the option of the Contractor, the grading
for cither 53 mm maximum size or 37.5 mm
maximum size shall be used, except that once a
grading is selected, it shall not be changed without
the Engineer’s approval.
TABLE 400.12. AGGREGATE GRADING

REQUIREMENTS
Sieve Size Per cent passing by we

53 mm max. size 37.5
63 mm 100
45 mm 87-100
22.4 mm 50-85
5.6 mm 25-45
710 micron 10-25
90 micron 2-9
TABLE 400-13. PHYSICAL REQUIREMENTS

OF COARSE AGGREGATES
FOR CRUSHER-RUN
MACADAM BASE
Test Test Method R

1. *Los Angeles IS : 2386 4
Abrasion value or (Part-4)
*Aggregate IS : 2386 3
IS : 5640
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2. Combined IS : 2386 3
Flakiness and (Part-1)
Elongation Indices (Total)
3. **Water absorption IS : 2386 2

(Part-3) M
4. Liquid Limit of IS : 2720 N

material passing 425 micron (Part-5) 2
5. Plasticity Index IS : 2720 N

of material passing 425 micron (Part-5) 6

of the two tests.
** If the water absorption is more than 2 per
cent, soundness test shall be carried out as
per IS:2386 (Part-5).
*** To determine this combined proportion, the
flaky stone from a representative sample
should first be separated out. Flakiness index
is weight of flaky stone metal divided by
weight of stone sample Only the elongated
particles be separated out from the remaining
(non-flaky) stone metal. Elongation index is
weight of elongated particles divided by total
non-flaky particles. The value of flakiness
index and elongation index so found are
added up.
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410.3.1. Preparation of subgrade: Any ruts,

deformations or soft yielding places which occur in
the sub-base or subgrade shall be Corrected and
compacted to the required density before the
aggregate base course is placed thereon.
410.3.2. Spreading, watering, mixing and

compaction: The aggregate shall be uniformly
deposited on the approved subgrade by means of the
hauling vehicle with or without spreading devices.
Aggregate will be distributed over the surface to the
depth specified on the plans or as directed by the
Engineer.
After the base course material has been
deposited, it shall be thoroughly blade-mixed to full
depth of the layer by alternately blading die entire
layer to the centre and back to the edges of the road.
It shall then be spread and finished to the required
cross-section by means of a motor grader.
Water shall be applied prior to and during all
blading and processing operations to moisten the
material sufficiently to prevent segregation of the
fine and coarse particles. Water shall be applied in
sufficient amounts during construction to assist in
compaction.
Alternatively, mixing of the crusher run
material and water may be done in a mixing plant as
per Clause 406.3.3.
Compaction shall commence immediately
after the spreading operation. If the thickness of
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single compacted layer does not exceed 100 mm, a
smooth wheel roller of 80 to 100 kN weight may be
used. For a compacted single layer upto 200 mm the
compaction shall be done with the help of vibratory
roller of minimum static weight of 80 to 100 kN or
equivalent capacity roller. The speed of the roller
shall not exceed 5 km/h. Each layer of material shall
be compacted to not less ton 98 per cent of the
maximum density as determined by IS: 2720 (Part-
8).

Control of Work

with Section 900.

Crusher-run macadam base shall be

measured as finished work in position in cubic
metres.
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410.7. Rate
The Contract unit rate for crusher run

macadam base shall be payment in full for carrying
out the required operations including full
compensation for items as in Clause 401.8 (i) to (v).
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Base and Surface Courses
(Bituminous)
500
Base and Surface Courses
(Bituminous)
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Page 315 of 1427
501. GENERAL REQUIREMENTS FOR
BITUMINOUS
PAVEMENT LAYERS
501.1. General
Bituminous pavement courses shall be made

using the materials described in the following
Specifications.
The use of machinery and equipment
mentioned in various Clauses of these Specifications
is mandatory. Details of the machinery and
equipment are available in the Manual for
Construction and Supervision of Bituminous Works.
Equipment mandatory for any particular project shall
be in accordance with the Contract Specification for
that project.
501.2. Materials
501.2.1. Binder: The binder shall be an

appropriate type of bituminous material complying
with the relevant Indian Standard (IS), as defined in
the appropriate Clauses of these Specifications, or as
otherwise specified herein. The choice of binder
shall be stipulated in the Contract or by the Engineer.
Where penetration grades of bitumen are specified,
they are referred to by a single-figure designation in
accordance with IS:73. Thus bitumen grade 35 tefers
to a bitumen in the penetration range 30 to 40.
Where Modified Binder is specified, the Clause 521
of these Specifications shall apply.
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501.2.2. Coarse Aggregates: The coarse
aggregates shall consist of crushed rock, crushed
gravel or other hard material retained on the 2.36
mm sieve. They shall be clean, hard, durable, of
cubical shape, free from dust and soft or friable
matter, organic or other deleterious matter. Where
the Contractor’s selected source of aggregates have
poor affinity for bitumen, as a condition for the
approval of that source, the bitumen shall be treated
with approved anti-stripping agents, as per the
manufacturer’s recommendations, without additional
payment. Before approval of the source the
aggregates shall be tested for stripping.
The aggregates shall satisfy the physical
requirements set forth in the individual relevant
clause for the material in question.
Where crushed gravel is proposed for use as
aggregate, not less than 90% by weight of the
crushed material retained on the 4.75 mm sieve shall
have at least two fractured faces.
501.2.3. Fine Aggregates: Fine aggregates

shall consist of crashed
or naturally occurring material, or a combination of

the two, passim: 2.36mm sieve and retained on the
75 micron sieve. They shall be clean hard, durable,
dry and free from dust, and soft or friable matter,
organic or other deleterious matter.
501.2.4. Source of material: The source of
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all materials to be used on the project must be tested
to the satisfaction of and be expressly approved by
the Engineer. The Engineer may from time to time
withdraw approval of a specific source, or attach
conditions to the existing approval. Any change in
aggregate source for bituminous mixes, will require
a new mix design, and laying trials, where the mix is
based on a job mix design. Stockpiles from different
sources, approved or otherwise, shall be kept
separate, such that there is no contamination between
one material and another. Each
Page 318 of 1427

source submitted for approval shall contain sufficient
material for at least 5 days work.
501.3. Mixing
Pre-mixed bituminous materials, including

bituminous macadam, dense bituminous macadam,
semi-dense bituminous concrete and bituminous
concrete, shall be prepared in a hot mix plant of
adequate capacity and capable of yielding a mix of
proper and uniform quality with thoroughly coated
aggregates. Appropriate mixing temperatures can be
found in Table 500-5 of these Specifications; the
difference in temperature between the binder and
aggregate should at no time exceed 14°C. In order to
ensure uniform quality of the mix and better coating
of aggregates, the hot mix plant shall be calibrated
from time to time.
If a continuous mixing plant is to be used for
mixing the bituminous bound macadam, the
Contractor must demonstrate by laboratory analysis
that the cold feed combined grading is within the
grading limits specified for that bituminous bound
material. In the case of a designed job mix, the
bitumen and filler content shall be derived using this
combined grading. Further details are available in
the Manual for Construction and Supervision of
Bituminous Works.
501.4. Transporting
Bituminous materials shall be transported in
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clean insulated vehicles, and unless otherwise agreed
by the Engineer, shall be covered while in transit or
awaiting tipping. Subject to the approval of the
Engineer, a thin coating of diesel or lubricating oil
may be applied to the interior of the vehicle to
prevent sticking and to facilitate discharge of the
material.
501.5. Laying
501.5.1. Weather and seasonal limitations:

Laying shall be suspended while free-standing water
is present on the surface to be covered, or during
rain, fog and dust storms. After rain, the bituminous
surface, prime or tack coat, shall be blown off with a
high pressure air jet to remove excess moisture, or
the surface left to dry before laying shall start.
Laying of bituminous mixtures shall not be carried
out when the air temperature at the surface on which
it is to be laid is below 10°C or when die wind speed
at any temperature exceeds 40 km/h at 2m height
unless specifically approved by the Engineer.
501.5.2. Cleaning of surface: The surface on

which the bituminous work is to be laid shall be
cleaned of all loose and extraneous matter by means
of a mechanical broom or any other approved
equipment / method as specified in the contract. The
use of a high pressure air jet from a compressor to
remove dust or loose matter shall be available full
time on the site, unless otherwise specified in the
Contract.
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501.5.3. Spreading: Except in areas where a
mechanical paver cannot access, bituminous
materials shall be spread, levelled and tamped by an
approved self-propelled paving machine. As soon as
possible after arrival at site, the materials shall be
supplied continuously to the paver and laid without
delay.
The rate of delivery of material to the paver
shall be regulated to enable the paver to operate
continuously. The travel rate of the paver, and its
method of operations, shall
Page 321 of 1427

be adjusted to ensure an even and uniform flow of
bituminous material across the screed, free from
dragging, tearing and segregation of the material. In
areas with restricted space where a mechanical paver
cannot be used, the material shall be spread, raked
and levelled with suitable hand tools by experienced
staff, and compacted to the satisfaction of the
Engineer.
The minimum thickness of material laid in
each paver pass shall be in accordance with the
minimum values given in the relevant parts of these
Specifications. When laying binder course or
wearing course approaching an expansion joint of a
structure, machine laying shall stop 300mm short of
the joint. The remainder of the pavement up to the
joint, and the corresponding area beyond it, shall be
laid by hand, and the joint or joint cavity shall be
kept clear of surfacing material.
Bituminous material, with a temperature
greater than 145°C, shall not be laid or deposited on
bridge deck waterproofing systems, unless
precautions against heat damage have been approved
by the Engineer
Hand placing of pre-mixed bituminous
materials shall only be permitted in the following
circumstances:
(i) For laying regulating courses of
irregular shape and varying thickness.
(ii) In confined spaces where it is
impracticable for a paver to operate.
(iii) For footways.
(iv) At the approaches to expansion joints
Page 322 of 1427

at bridges, viaducts or other
structures.
(v) For laying mastic asphalt in
(vi) For filling of potholes.
(vii) Where directed by the Engineer.
Manual spreading of pre-mixed wearing
course material or the addition of such material by
hand-spreading to the paved area, for adjustment of
level, shall only be permitted in the following
circumstances:
(i) At the edges of the layers of material
and at gullies and manholes.
(ii) At the approaches to expansion joints
at bridges, viaducts or other
structures.
(iii) As directed by the Engineer.
501.5.4. Cleanliness and overlaying:

Bituminous material shall be kept clean and
uncontaminated. The only traffic permitted to run on
bituminous material to be overlaid shall be that
engaged in laying and compacting the next course
or, where a binder course is to be sealed or surface
dressed, that engaged on such surface treatment.
Should any bituminous material become
contaminated the Contractor shall make it good to
the satisfaction of the Engineer, in compliance with
Clause 501.8.
Binder course material shall not remain
uncovered by either the wearing course or surface
treatment, whichever is specified in the Contract, for
Page 323 of 1427

more than three consecutive days after being laid.
The Engineer may extend this period, by the
minimum amount of time necessary, because of
weather conditions or for any other reason. If the
surface of the base course is subjected to traffic, or
not covered within three days, a tack coat shall be
applied, as directed by the Engineer.
501.6. Compaction
Bituminous materials shall be laid and

compacted in layers which enable the specified
thickness, surface level regularity requirements and
compaction to be achieved.
Page 324 of 1427

Compaction of bituminous materials shall
commence as soon as possible after laying.
Compaction shall be substantially completed before
the temperature falls below the minimum rolling
temperatures stated in the relevant part of these
Specifications. Rolling of the longitudinal joints
shall be done immediately behind the paving
operation. After this, rolling shall commence at the
edges and progress towards the centre longitudinally
except that on super elevated and unidirectional
cambered portions, it shall progress from the lower
to the upper edge parallel to the centre line of the
pavement. Rolling shall continue until all roller
marks have been removed from the surface. All
deficiencies in the surface after laying shall be made
good by the attendants behind the paver, before
initial rolling is commenced. The initial or
breakdown rolling shall be done with 8-10 tonnes
dead weight smooth-wheeled rollers. The
intermediate rolling shall be done with 8-10 tonnes
dead weight or vibratory roller or with a pneumatic
tyred roller of 12 to 15 tonnes weight having nine
wheels, with a tyre pressure of at least 5.6 kg/sq.cm.
The finish rolling shall be done with 6 to 8 tonnes
smooth wheeled tandem rollers.
Where compaction is to be determined by
density of cores the requirements to prove the
performance of rollers shall apply in order to
demonstrate that the specified density can be
achieved. In such cases the Contractor shall
nominate the plant, and the method by which he
intends to achieve the specified level of compaction
Page 325 of 1427

and finish at temperatures above the minimum
specified rolling temperature. Laying trials shall then
demonstrate the acceptability of the plant and
method used.
Bituminous materials shall be rolled in a
longitudinal direction, with the driven rolls nearest
the paver. The roller shall first compact material
adjacent to joints and then work from the lower to
the upper side of the layer, overlapping on
successive passes by at least one-third of the width
of the real roll or, in the case of a pneumatic-tyred
roller, at least the nominal width of 300mm
In portions with super-elevated and uni-
directional camber, after the edge has been rolled,
the roller shall progress from the lower to the upper
edge.
Rollers should move at a speed of not more
than 5 km per hour. The roller shall not be permitted
to stand on pavement which has not been fully
compacted, and necessary precautions shall be taken
to prevent dropping of oil, grease, petrol or other
foreign matter on the pavement either when the
rollers are operating or standing. The wheels of
rollers shall be kept moist with water, and the spray
system provided with the machine shall be in good
working order, to prevent the mixture from adhering
to the wheels. Only sufficient moisture to prevent
adhesion between the wheels of rollers and the
mixture should be used. Surplus water shall not be
allowed to stand on the partially compacted
pavement
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501.7. Joints
Where longitudinal joints are made in pre-

mixed bituminous materials, the materials shall be
fully compacted and the joint made flush in one of
the following ways; only method (iii) shall be used
for transverse joints:
(i) by beating the joints with an approved
joint heater when the adjacent width
is being laid, but without cutting back
or coating with binder. The heater
shall raise the temperature of the full
depth of material, to within the
specified range of minimum rolling
temperature and maximum
temperature at any stage for the
material, for a width not less than 75
mm. The Contractor shall have
equipment available, for use in the
event of a heater breakdown, to form
joints by method (iii);
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(ii) by using two or more pavers
operating in echelon, where this is
practicable, and in sufficient
proximity for adjacent widths to be
fully compacted by continuous
rolling;
(iii) by cutting back the exposed joint, for
a distance equal to the specified layer
thickness, to a vertical face,
discarding all loosened material and
coating the vertical face completely
with 80/100 penetration grade hot
bitumen, or cold-applied bitumen, or
polymer modified adhesive bitumen
tape with a minimum thickness of 2
mm, before the adjacent width is laid.
All joints shall be offset at least 300 mm
from parallel joints in the layer beneath or as
directed, and in a layout approved by the Engineer.
Joints in the wearing course shall coincide with
either the lane edge or the lane marking, which ever
is appropriate. Longitudinal joints shall not be
situated in wheel track zones.
501.8. Preparation of Surface
501.8.1. Scope : This work shall consist of

preparing an existing granular or black-topped
surface bituminous course. The work shall be
performed on such widths and lengths as shown on
the drawings or as instructed by the Engineer. The
existing surface shall be firm and clean, and treated
Page 328 of 1427

with Prime or Tack coat as shown on the drawings as
otherwise stated in the Contract.
501.8.2. Materials
501.8.2.1. For scarifying and re-laying the

granular surface: The material used shall be coarse
aggregate salvaged from the scarification of the
existing granular base course supplemented by fresh
coarse aggregate and screenings so that aggregates
and screenings thus supplemented correspond to
Clause 404: Water Bound Macadam or Clause 406:
Wet Mix Macadam
501.8.2.2. For patching potholes and

sealing cracks: Where the existing surface to be
overlaid is bituminous, any existing potholes and
cracks shall be repaired and sealed in accordance
with Clauses 3004.2 and 3004.3, or as directed by
the Engineer.
501.8.2.3. For profile corrective course: A

profile corrective course for correcting the existing
pavement profile shall be laid to varying thickness as
shown on the Drawings, or as indicated in the
Contract Documents. The profile corrective course
shall be laid to tolerances and densities as specified
for wearing course if a single layer, or base course, if
it is to be covered with a wearing course layer.
501.8.2.4. Profile corrective course and its

application: The type of material for use as profile
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corrective course shall be as shown on the drawings
or as directed by the Engineer. Where it is to be laid
as part of the overlay/strengthening course, the
profile corrective course material shall be of the
same specification as that of the overlay/
strengthening course. However, if provided as a
separate layer, it shall be of the specification and
details given in the contract drawings.
(i) Any high spots in the existing surface
shall be removed by a milling
machine or other approved method,
and all loose material shall be
removed to the satisfaction of the
Engineer.
(ii) Where the maximum thickness of
profile corrective course will be not
more than 40 mm, the profile
corrective course shall be constructed
as an
Page 330 of 1427

integral part of the overlay course. In
other cases, the profile corrective
course shall be constructed as a
separate layer, adopting such
construction procedures and using
such equipment as approved by the
Engineer, to lay the specified type of
material, to thickness and tolerance as
specified, for the coarse, to be
provided.
501.8.3. Construction Operations
501.8.3.1. Preparing existing granular

surface: Where the existing surface is granular, all
loose materials shall be removed, and the surface
lightly watered where the profile corrective course to
be provided as a separate layer is also granular.
Where the profile corrective course of bituminous
material is to be laid over the existing granular
surface, the latter shall, after removal of all loose
material, be primed in accordance with Clause 502.
The surface finish of all granular layers on
which bituminous works are to be placed, shall,
unless otherwise specifically instructed by the
Engineer, be free from dust. All such layers must be
capable of being swept, after the removal of any
non-integral loose material, by means of a
mechanical broom, without shedding significant
quantities of material and dust removed by air jet,
washing, or other means approved by the Engineer.
After cleaning the surface shall be correct to
Page 331 of 1427

line and level, within the tolerances specified for
base course.
501.8.3.2. Scarifying existing bituminous

surface: Where specified or shown on the drawings,
the existing bituminous layer in the specified width
shall be removed with care and without causing
undue disturbance to the underlying layer, by a
suitable method approved by the Engineer. After
removal, all loose and disintegrated material, the
underlying layers which might have been disturbed
should be suitably reworked and compacted to line
and level. After supplementing the base material as
necessary with suitable fresh stone, the compacted
finished surface shall be primed in accordance with
Clause 502. Reusable materials shall be stacked as
directed by the Engineer within 1000 m of their
origin.
501.83.3. Patching of potholes and sealing

of cracks: Where the existing surface to be overlaid
is bituminous, any existing potholes and cracks shall
be repaired and sealed in accordance with clauses
3004.2 and 3004.3, or as directed by the Engineer.
501.8.3.4. Laying the profile corrective

course
501.8.3.4.1. Laying on granular base: After

preparing the granular surface in accordance with
Clauses 501.8.3.1 and 501.8.3.2, the profile
corrective course shall be laid using material as
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described in Clauses 501.8.2.3 and 501.8.2.4, or as
otherwise described in the Contract, and compacted
to the requirements of the particular Specification.
501.8.3.4.2. Laying on existing bituminous

surface: The existing bituminous surface shall be
prepared in accordance with Clause 501.8.3.3, and
after applying a tack coat conforming to Clause 503,
the bituminous profile corrective course shall be laid
and compacted to the requirements of the particular
Specification.
Page 333 of 1427

501.8.3.4.3. Correction of local
depressions: Where local sags or depressions occur
in the existing pavement, a specific filling operation
shall be instructed by the Engineer, which should be
laid in accordance with Figure 500-1. Normally, the
maximum layer thickness at any point should not
exceed 100 mm. In placing multiple lifts, they
should be arranged according to the correct method
as illustrated.
For correction of camber or super-elevation
of the existing carriageway, the method shown in
Figure. 500-2 shall be adopted, depending on the
profile of the existing carriageway.
501.8.3.5. Covering the profile corrective

courses: Profile corrective course particularly shall
be so planned that the layer shall be covered by the
designed base/wearing course at the earliest
opportunity, before opening to regular traffic.
501.8.4. Surface finish and quality control

of work: The relevant provisions of Section 900
shall apply.
501.8.5. Arrangements for traffic: During

construction operations, arrangements for traffic
shall be made in accordance with the provisions of
Clause 112.
501.8.6. Environmental protection: The

provisions of Clause 111 and the provision of
Annexure A to Clause 501 shall apply.
Page 334 of 1427

501.8.7. Measurement for payment
501.8.7.1. Potholes and cracks: The work of

filling potholes shall be measured separately and be
paid for in square metres.
The work of filling cracks by applying fog
spray or emulsion slurry seal shall be measured in
square metres, for the area covered by the spray.
Page 335 of 1427

Page 336 of 1427
Note: Profile corrective course material to be in
accordance with the lift thickness
Figure. 500-1. Methods for providing corrective
course for short sags and depressions
Page 337 of 1427

Page 338 of 1427
The work in filling cracks larger than 3mm in
width shall be measured and paid for on a linear
metre basis.
501.8.7.2. Scarifying: Scarifying the existing

bituminous surface shall be measured on a square
metre basis.
501.8.7.3. Profile corrective course: Profile

corrective course shall be measured as the volume
instructed and compacted in position and measured
in cubic metres, or in tonnage, as stipulated in the
Contract. The volume shall be calculated by plotting
the exact profile of profile corrective course as
required, and laid, superimposed on the existing
pavement profile. Cross-sectional areas of the profile
corrective course shall be measured at intervals as
used in the design, or as determined by the Engineer,
and the volume shall be calculated using the method
of end areas.
501.8.7.4 Prime coat: Prime coat is to be

measured and paid for on a per square metre basis.
501.8.7.5 Tack coat: This is to be a

PROVISIONAL item, which may be used in-part or
not at all, at the Engineers direction, and is to be
measured and paid for, if used, en a square metre
basis.
501.8.8. Rates
Page 339 of 1427

501.8.8.1. Rate for scarifying: The contract
unit rate for scarifying existing bituminous surfaces,
including repairing / reworking disturbed underlying
layers and removing and stacking reusable /
unusable materials, shall include for but not
necessarily be limited to, the cost of all labour,
supply of materials needed for repair / reworking,
hire charges of tools and plant, and transportation of
scarified materials within 1000 m of their origin.
501.8.8.2. Rate for premixed bituminous

material: The contract unit rate for premixed
bituminous material shall be payment in full for
carrying out the required operations including full
compensation for, but not necessarily limited to:
(i) Making arrangements for traffic to
treatment to verge, shoulders and
(ii) Preparation of the surface to receive
the material.
(iii) Providing all materials to be
incorporated in the work including
arrangement for stock yards, all
royalties, fees, rents where necessary
and all leads and lifts;
(iv) Mixing, transporting, laying and
compacting the mix, as specified.
(v) All labour, tools, equipment, plant
including installation of hot mix
plant, power supply units and all
Page 340 of 1427

machinery, incidental to complete the
work to these Specifications;
(vi) Carrying out the work in part widths
of the road where directed;
(vii) Carrying out all tests for control of
quality; and
(viii) The rate shall cover the provision of
bitumen at the rate specified in the
contract, with the provision that the
variation in actual percentage of
bitumen used will be assessed and the
payment adjusted accordingly.
Page 341 of 1427

(ix) The rates for premixed material are to
include for all wastage in cutting of
joints etc.
(x) The rates are to include for all
necessary testing, mix design,
transporting and testing of samples,
and cores. If there is not a project
specific laboratory, the Contractor
must arrange to carry out all
necessary testing at an outside
Laboratory, approved b the Engineer,
and all costs incurred are deemed to
be included in the rate quoted the
material.
(xi) The cost of all plant and laying trials
as specified to prove the mixing and
lays, methods is deemed to be
included in the Contractor’s rates for
the material.
501.8.8.3. Rate for potholes and crack

sealing: The rate for patching potholes shall include
for breaking out, trimming edges, cleaning out
painting edges and bottom with bitumen, and filling
and compacting the excavation with the specified
material. The rate should be inclusive of all plant,
tools, labour and materials, transport, and disposal of
surplus material,
The contract unit rate for sealing cracks by
applying fog spray shall be inclusive of providing all
materials, tools, labour and plant and carrying out
the work. The contract unit rate for sealing cracks by
Page 342 of 1427

providing emulsion slurry seal shall be as set forth in
Clause 516.9.
The contract unit rate for crack sealing 3mm
to 6mm cracks with Straight run or other specified
bitumen, shall be based on either a square metre
basis, or linear metre of cracks as measured, as
stipulated by the Contract.
The contract unit rate for cracks between
6mm and 15mm is to be measured on a linear metre
basis, and the rate is to include for all materials,
tools, plant, labour, and transport.
Page 343 of 1427

Annexure ‘A’ to Clause 501
Annexure ‘A
PROTECTION OF THE
ENVIRONMENT
1. General
1.1. This section of the Specification sets out
limitations on the Contractor’s activities
specifically intended to protect the
environment.
1.2. The Contractor shall take all necessary
measures and precautions and otherwise
ensure that the execution of the works and all
associated operations on site or off-site are
carried out in conformity with statutory and
regulatory environmental requirements
including those prescribed elsewhere in this
document.
1.3. The Contractor shall take all measures and
precautions to avoid any nuisance or
disturbance arising from the execution of the
Works. This shall wherever possible be
achieved by suppression of the nuisance at
source rather than abatement of the nuisance
once generated.
1.4. In the event of any spoil, debris, waste or any
deleterious substance from the Site being
deposited on any adjacent land, the
Contractor shall immediately remove all such
material and restore the affected area to its
original state to the satisfaction of the
Page 344 of 1427

Engineer.
2. Water Quality
2.1. The Contractor shall prevent any interference

with the supply to or abstraction from, and
prevent any pollution of, water resources
(including underground percolating water) as
a result of the execution of the Works.
2.2. Areas where water is regularly or repetitively
used for dust suppression purposes shall be
laid to fall to specially-constructed settlement
tanks to permit sedimentation of particulate
matter. After settlement, the water may be re-
used for dust suppression and rinsing.
2.3. All water and other liquid waste products
arising on the Site shall be collected and
disposed of at a location on or off the Site
and in a manner that shall not cause either
nuisance or pollution.
2.4. The Contractor shall not discharge or deposit
any matter arising from the execution of the
Works into any waters except with the
permission of the Engineer and the regulatory
authorities concerned.
2.5. The Contractor shall at all times ensure that
all existing stream courses and drains within,
and adjacent to, the Site are kept safe and
free from any debris and any materials
arising from the Works.
2.6. The Contractor shall protect all watercourses,
waterways, ditches, canals, drains, lakes and
Page 345 of 1427

the like from pollution as a result of the
execution of the Works.
3. Air Quality
3.1. The Contractor shall devise and arrange
methods of working to minimise dust,
gaseous or other air-borne emissions and
carry out the Works in such a manner as to
minimise adverse impacts on air quality.
3.2. The Contractor shall utilise effective water
sprays during delivery manufacture,
processing and handling of materials when
dust is likely to be created, and to dampen
stored materials during dry and windy
weather. Stockpiles of friable materials
shall be covered with clean tarpaulins,
with application of sprayed water during
dry and windy weather. Stockpiles of
material or debris shall be dampened prior
to their movement, except where this is
contrary to the Specification.
3.3. Any vehicle with an open load-carrying
area used for transporting potentially dust
producing material shall have properly
fitting side and tail boards. Materials
having the potential to produce dust shall
not be loaded to a level higher than the
side and tail boards, and shall be covered
with a clean tarpaulin in good condition.
The tarpaulin shall be properly secured and
extend at least 300 mm over the edges of
the side and tail boards.
Page 346 of 1427

3.4. In the event that the Contractor is
permitted to use gravel or earth roads for
haulage, he shall provide suitable measures
for dust palliation, if these are, in the
opinion of the Engineer, necessary. Such
measures may include spraying the road
surface with water at regular intervals.
4. Noise
4.1. The Contractor shall consider noise as an
environmental constraint in his planning and
execution of the Works.
4.2. The Contractor shall take all necessary
measures so that the operation of all
mechanical equipment and construction
processes on and off the Site shall not cause
any unnecessary or excessive noise, taking
into account applicable environment
requirements. The Contractor shall use all
necessary measures and shall maintain all
plant and silencing equipment in good
condition so as to minimise the noise
emission during construction works.
5. Control of Wastes
5.1. The Contractor shall control the disposal of
all forms of waste generated by the
construction operations and in all associated
activities. No uncontrolled deposition or
dumping shall be permitted. Wastes to be so
controlled shall include, but shall not be
limited to, all forms of fuel and engine oils,
Page 347 of 1427

all types of bitumen, cement, surplus
aggregates, gravels, bituminous mixtures etc.
The Contractor shall make specific provision
for the proper disposal of these and any other
waste products, conforming to local
regulations and acceptable to the Engineer.
6. Emergency Response
6.1. The Contractor shall plan and provide for
remedial measures to be implemented in
the event of occurrence of emergencies
such as spillages of oil or bitumen or
chemicals.
6.2. The Contractor shall provide the Engineer
with a statement of the measures he intends
to implement in the event of such an
emergency which shall include a statement
of how he intends to provide personnel
adequately trained to implement such
measures.
7. Measurement
7.1. No separate measurement shall be made in
respect of compliance by the Contractor with
the provisions of this Section of the
Specification. The Contractor shall be
deemed to have made allowance for such
compliance with these provisions in the
preparation of his prices for items of work
included in the Bills of Quantities and full
compensation for such compliance will be
deemed to be covered by them.
Page 348 of 1427

502. PRIME COAT OVER GRANULAR
BASE
502.1. Scope
This work shall consist of the application of a

single coat of low viscosity liquid bituminous
material to a porous granular surface preparatory to
the superimposition of bituminous treatment OB.
mix.
502.2. Materials
502.2.1. Primer: The choice of a bituminous

primer shall depend upon the porosity characteristics
of the surface to be primed as classified in IRC: 16.
These are:
(i) Surfaces of low porosity; such as wet
mix macadam and water bound
macadam,
(ii) Surfaces of medium porosity; such as
cement stabilised soil base,
(iii) Surfaces of high porosity; such as a
gravel base.
502.2.2. Primer viscosity: The type and

viscosity of the primer shall comply with the
requirements of IS 8887, as sampled and tested for
bituminous primer in accordance with these
standards. Guidance on viscosity and rate of spray is
given in Table 500-1.
Page 349 of 1427

TABLE 500-1. VISCOSITY REQUIREMENT
AND QUANTITY OF LIQUID
BITUMINOUS PRIMER
Type of surface Kinematic Viscosity of Quantity of Liq
Primer at 60°C Material p
(Centistokes) (k
Low porosity 30-60 6
Medium porosity 70- 140 9t
High porosity 250 - 500 12
502.2.3. Choice of primer: The primer shall

be bitumen emulsion, complying with IS 8887 of a
type and grade as specified in the Contract or as
directed by the Engineer. The use of medium curing
cutback as per IS 217 shall be restricted only for
sites at sub-zero temperatures or for emergency
applications as directed by the Engineer.
502.3. Weather and Seasonal Limitations
Bituminous primer shall not be applied to a

wet surface (see 502.4.2) or during a dust storm or
when the weather is foggy, rainy or windy or when
the tempeiature in the shade is less than 10°C.
Surfaces which are to receive emulsion primer
should be damp, but no free or standing water shall
be present.
502.4. Construction
Page 350 of 1427

502.4.1. Equipment: The primer distributor
shall be a self-propelled or towed bitumen pressure
sprayer equipped for spraying the material uniformly
at specified rates and temperatures. Hand spraying of
small areas, inaccessible to the distributor, or in
Page 351 of 1427

narrow strips shall be sprayed with a pressure hand
sprayer, or as directed by the Engineer.
502.4.2. Preparation of road surface: The

surface to be primed shall be prepared in accordance
with Clauses 501.8. and 902 as appropriate.
Immediately prior to applying the primer the surface
shall be carefully swept clean of dust and loose
particles, care being taken not to disturb the
interlocked aggregate. This is best achieved when
the surface layer is slightly moist (lightly sprayed
with water and the surface allowed to dry) and the
surface should be kept moist until the primer is
applied.
502.4.3. Application of bituminous primer:

The viscosity and rate of application of the primer
shall be as specified in the Contract, or as
determined by site trials carried out as directed by
the Engineer. Where a geosynthetic is proposed for
use, the requirements of Clauses 703.3.2 and 703.4
shall apply. The bituminous primer shall be sprayed
uniformly in accordance with Clause 501 The
method for application of the primer will depend on
the type of equipment to be used, size of nozzles,
pressure at the spray bar and speed of forward
movement. The Contractor shall demonstrate at a
spraying trial, that the equipment and method to be
used is capable of producing a uniform spray, within
the tolerances specified.
502.4.4. Curing of primer and opening to
Page 352 of 1427

traffic: A primed surface shall be allowed to cure
for at least 24 hours or such other period as is found
to be necessary to allow all the volatiles to evaporate
before any subsequent surface treatment or mix is
laid. Any unabsorbed primer shall first be blotted
with an application of sand, using the minimum
quantity possible. A primed surface shall not be
opened to traffic other than that necessary to lay the
next course. A very thin layer of clean sand may be
applied to the surface of the primer, to prevent the
primer picking up under the wheels of the paver and
the trucks delivering bituminous material to the
paver.
502.4.5. Tack coat: Over the primed surface,

a tack coat should be applied in accordance with
Clause 503.
502.5.Quality Control of Work
For control of the quality of materials

supplied and the works carried out, the relevant
provisions of Section 900 shall apply.
During construction operations, arrangements

for traffic shall be made in accordance with the
provisions of Clause 112.
Page 353 of 1427

Prime coat shall be measured in terms of
surface area of application in square metres.
Page 354 of 1427

502.8. Rate
The contract unit rate for prime coat with

adjustments as described in Clause 502.7 shall be
components listed in Clause 401.8 (i) to (v) and as
applicable to the work specified in these
Specifications. Payment shall be made on the basis
of the provision of prime coat at an application rate
of 0.5 kg per square metre, with adjustment, plus or
minus, for the variation between this amount and the
actual amount approved by the Engineer after the
preliminary trials referred to in Clause 502.4.3.
503. TACK COAT
503.1. Scope
This work shall consist of the application of a

single coat of low viscosity liquid bituminous
material to an existing bituminous road surface
preparatory to the superimposition of a bituminous
mix, when specified in the Contract or instructed by
the Engineer.
503.2. Materials
503.2.1. Binder: The binder used for tack

coat shall be bitumen emulsion complying with IS
8887 of a type and grade as specified in the Contract
or as directed by the Engineer. The use of cutback
Page 355 of 1427

bitumen, as per IS 217 shall be restricted only for
sites at sub-zero for emergency applications as
Bituminous material shall not be applied to a

wet surface or during a dust storm or when the
weather is foggy, rainy or windy or when the
temperature in the shade is less than 10°C. Where
the tack coat consists of emulsion, the surface shall
be slightly damp, but not wet. Where the tack coat is
of cutback bitumen, the surface shall be dry.
503.4. Construction
503.4.1. Equipment: The tack coat

distributor shall be a self-propelled or towed bitumen
pressure sprayer, equipped for spraying the material
uniformly at a specified rate. Hand spraying of small
areas, inaccessible to the distributor, or in narrow
strips, shall be sprayed with a pressure hand sprayer,
503.4.2. Preparation of base: The surface

on which the tack coat is to De applied shall be clean
and free from dust, dirt, and any extraneous material,
and be otherwise prepared in accordance with the
requirements of Clauses 501.8 and 902 as
appropriate. Immediately before the application of
the tack coat, the surface shall be swept clean with a
mechanical broom, and high pressure air jet, or by
Page 356 of 1427

other means as directed by the Engineer.
503.4.3. Application of tack coat: The

application of tack coat shall be at the rate specified
in the Contract, and shall be applied uniformly. If
rate of application of Tack Coat is not specified in
the contract then it shall be at the rate specified in
Table 500-2.
Page 357 of 1427

The normal range of spraying
TABLE 500-2. RATE OF

APPLICATION OF TACK COAT
Type of Surface Quantity of liquid

bituminous
material in Kg per
sq. m. area
i) Normal bituminous 0.20 to 0.25
surfaces
ii) Dry and hungry 0.25 to 0.30
bituminous surfaces
iii) Granular surfaces 0.25 to 0.30
treated with primer
iv) Non bituminous
surfaces
a) Granular base (not 0.35 to 0.40
primed)
b) Cement concrete 0.30 to 0.35
pavement
temperature for a bituminous emulsion shall be 20°C

to 70°C and for a cutback, 50°C to 80°C if RC-
Page 358 of 1427

70/MC-70 is used. Where a geosynthetic is proposed
for use, the provisions of Clauses 703.3.2 and
703.4.4 shall apply. The method of application of the
tack coat will depend on the type of equipment to be
used, size of nozzles, pressure at the spray bar, and
speed of forward movement. The Contractor shall
demonstrate at a spraying trial, that the equipment
and method to be used is capable of producing a
uniform spray, within the tolerances specified.
Where the material to receive an overlay is a
freshly laid bituminous layer, that has not been
subjected to traffic, or contaminated by dust, a tack
coat is not mandatory where the overlay is
completed within two days.
503.4.4. Curing of tack coat: The tack coat

shall be left to cure until all the volatiles have
evaporated before any subsequent construction is
started. No plant or vehicles shall be allowed on the
tack coat other than those essential for the
construction.
503.5. Quality Control of Work


arrangements for traffic shall be made in accordance
Page 359 of 1427

with the provisions of Clause 112.
Tack coat shall be measured in terms of

surface area of application in square metres.
Page 360 of 1427

503.8. Rate
The contract unit rate for tack coat shall be

operations including for all components listed in
Clause 401.8 (i) to (v) and as applicable to the work
specified in these Specifications. The rate shall cover
the provision of tack coat at 0.2 kg per square metre,
with the provision that the variance in actual quantity
of bitumen used will be assessed and the payment
adjusted accordingly.
504. BITUMINOUS MACADAM
504.1. Scope
This work shall consist of construction in a

single course having 50mm to 100mm thickness or
in multiple courses of compacted crushed aggregates
premixed with a bituminous binder on a previously
prepared base to the requirements of these
Specifications. Bituminous macadam is more open
graded than the dense graded bituminous materials
described in Clauses 507, 508 and 509.
504.2. Materials
504.2.1. Bitumen: The bitumen shall be

paving bitumen of Penetration Grade complying
with Indian Standard Specifications for “Paving
Bitumen” IS:73, and of the penetration indicated in
Table 500-4.
Page 361 of 1427

504.2.2. Coarse aggregates: The coarse
matter, organic or other deleterious matter. Where
the Contractor’s selected source of aggregates have
poor affinity for bitumen, as a condition for the
approval of that source, the bitumen shall be treated
with approved anti-stripping agents, as per the
payment. Before approval of the source, the
aggregates shall be tested for stripping.
The aggregates shall satisfy the physical
requirements set forth in Table 500-3.
504.2.3. Fine aggregates: Fine aggregates

shall consist of crushed or naturally occurring
material, or a combination of the two, passing 2.36
mm sieve and retained on 75 micron sieve. They
shall be clean, hard, durable, dry and free from dust,
and soft or friable matter, organic or other
deleterious matter.
Page 362 of 1427

REQIREMENTS FOR COARSE
AGGREGATES FOR
BITUMINOUS MACADAM
Property Test
Cleanliness Grain size analysis1 Max 5%
Particle shape Flakiness and Elongation Index M

(Combined)2
Strength* Los Angeles Abrasion Value3 M
Aggregate Impact Value3 M
Durability Soundness:4
Sodium Sulphate M
Magnesium Sulphate M
Water Absorption Water absorption5
Stripping Coaling and Stripping of Bitumen Minimum
Aggregate Mixtures6
Water Sensitivity7 Retained Tensile Strength
Notes : 1. IS : 2386 Part 1
4. IS : 2386 Part 5
2. IS : 2386 Part 1
5. IS : 2386 Part 3
(the elongation test to be done only on non-
flaky aggregates in the sample)
3. IS: 2386 Part 4*
6. IS: 6241
7. The water sensitivity test is only required
if the minimum retained coating in the
stripping test is less than 95%.
* Aggregate may satisfy requirements of
Page 363 of 1427

either of these two tests.
504.2.4. Aggregate grading and binder

content: When tested in accordance with IS: 2386
Part 1 (wet sieving method), the combined aggregate
grading for the particular mixture shall fall within
the limits shown in Table 500-4 for the grading
specified in the Contract. The type and quantity of
bitumen, and appropriate thickness, are also
indicated for each mixture type.
504.2.5. Proportioning of material: The

aggregates shall be proportioned and blended to
produce a uniform mixture complying with the
requirements of Table 500-4. The binder content
shall be within a tolerance of ± 0.3 per cent by
weight of total mixture when individual specimens
are taken for quality control tests in accordance with
the provisions of Section 900.

The provisions of Clause 501.5.1 shall apply.
Page 364 of 1427

TABLE 590-4. COMPOSITION OF
BITUMINOUS MACADAM
Mix designation Grading 1 G

Nominal aggregate 40mm 8
size Layer thickness 80-100mm 5
IS Sieve (mm) Cumulative % by weight of total agg
45 100
37.5 90-100
26.5 75-100
19 -
13.2 35-61
4.75 13-22
2.36 4-19
0.3 2-10
0.075 0-8
Bitumen content, % 3.1-3.4
by weight of total
mixture1
Bitumen grade 35 to 90
Notes: 1. Appropriate bitumen contents for
conditions in cooler areas of India
may be up to 0.5% higher subject to
504.3.2. Preparation of the base: The base

on which bituminous macadam is to be laid shall be
prepared, shaped and compacted to the required
profile in accordance with Clauses 501.8 and 902.3
as appropriate, and a prime coat, shall be applied in
accordance with Clause 502 where specified, or as
Page 365 of 1427

504.3.3. Tack coat : A tack coat in
accordance with Clause 503 shall be applied as
required by the Contract documents, or as directed
by the Engineer.
504.3.4. Preparation and transportation of

the mixture: The provisions of Clauses 501.3 and
501.4 shall apply.
504.3.5. Spreading: The provisions of
Clauses 501.5.3 shall apply.
TABLE 500-5. MANUFACTURING AND

ROLLING TEMPERATURES
Bitumen Bitumen Aggregate Mixed Material Rolling (0

Penetration Mixing (0C) Mixing (0C) (0C)
35 160-170 160-175 170 Maximum 100 Minim
65 150-165 150-170 165 Maximum 90 Minimu
90 140-160 140-165 155 Maximum 80 Minimu
504.3.6. Rolling: Compaction shall be

carried out in accordance with the provisions of
Clauses 501.6 and 501.7.
Rolling shall be continued until the specified
density is achieved, or where no density is specified,
until there is no further movement under the roller.
The required frequency of testing is defined in
Clause 903.
Page 366 of 1427

of Work
The surface finish of the completed

construction shall conform to the requirements of
Clause 902. For control of the quality of materials
504.5. Protection of the Layer
The bituminous macadam shall be covered

with either the next pavement course or wearing
course, as the case may be, within a maximum of
forty-eight hours. If there is to be any delay, the
course shall be covered by a seal coat to the
requirement of Clause 513 before opening to any
traffic. The seal coat in such cases shall be
considered incidental to the work and shall not be
paid for separately.

Bituminous macadam shall be measured as

finished work in cubic metres or by weight in metric
tonnes, where used as regulating course, or square
Page 367 of 1427

metres at the specified thickness as indicated in the
Contract or shown on the drawings, or as otherwise
504.8. Rate
The contract unit rate for bituminous

macadam shall be payment in full for carrying out
the required operations as specified. The rate shall
include for, all components listed in Clause
501.8.8.2. (i) to (xi).
505. BITUMINOUS PENETRATION

MACADAM
505.1. Scope
The work shall consist of construction of one

or more layers of compacted crushed coarse
aggregates with alternate applications of bituminous
binder and key aggregates in accordance with the
requirements of these Specifications to be used as a
base course on roads, subject to the requirements of
the overall pavement design, in conformity with the
lines, grades and cross-sections shown on the
drawings or as directed by the Engineer. Thickness
of an individual course shall be 50 mm or 75 mm, or
other as specified.
505.2. Materials
505.2.1. Bitumen: The binder shall be
Page 368 of 1427

paving bitumen of suitable penetration grade within
the range of S-35 to S-90 or A-35 to A-90 (30/ 40 to
80/100) as per Indian Standards Specifications for
“Paving Bitumen” IS :73, or approved cutback
satisfying the
Page 369 of 1427

requirements of IS : 217 or 454. The actual grade of
bitumen or cutback to be used shall be as specified
505.2.2. Aggregates: The aggregates shall

satisfy the physical requirements set out in Clause
504.2.2. and Table 500-3. The coarse and key
aggregates shall conform to the grading given in
Table 500-6.
505.2.3. Quantities of materials: The

quantities of materials used for this work shall be as
specified in Table 500-6.
505.3.1. Weather and Seasonal

Limitations: The provisions of Clause 501.5.1. shall
apply.
505.3.2. Equipment : A mechanical broom,

compressor, self propelled or trailed bitumen
heater/distributor, mechanical aggregate spreader
and 8 to 10 tonne smooth steel wheel roller or
vibrating roller are required for the preparation of
Penetration Macadam.

on which the Penetration Macadam Course is to be
laid shall be prepared, shaped and compacted to the
specified lines, grades and sections to Clauses 501
and 902 as appropriate, or as directed by the
Page 370 of 1427

Engineer. A prime coat, where specified, shall be
applied over the base in accordance with Clause 502
or as directed by the Engineer. A tack coat as per
Clause 503 shall be applied.
505.3.4. Spreading coarse aggregates: The

coarse aggregate shall be dry and clean and free
from dust, and shall be spread uniformly and evenly
at the rate specified in Table 500-6. It shall be spread
by a self-propelled or tipper tail mounted aggregate
spreader capable of spreading aggregate uniformly at
the specified rates over the required widths. The
surface of the layer shall be carefully checked with
camber templates to ensure correct line and level and
cross fall. The spreading shall be carried out such
that the rolling and penetrating operations can be
completed on the same day. Segregated aggregates
or aggregates contaminated with foreign material
shall be removed and replaced.
Page 371 of 1427

PENETRATION MACADAM
Cumulative per cent by weight of total agg

For 50 mm compacted For 75
Thickness T
IS Sieve Coarse Key Coarse
Designation (mm) Aggregate Aggregate Aggregate
63 — — 100
45 100 __ 58-82
26.5 37-72 — --
22.4 — 100 5-27
13.2 2-20 50 - 75 —
11.2 — — —
5.6 — 5-25 —
2.8 0-5 0-5 0-5
Approx. Loose
aggregate 0.06 0.015 0.09
quantities cu.m/m2
Binder quantity
(penetration 5
grade)(1) (kg/m2)
Note: (1) If cutback bitumen is used, adjust

binder quantity such that the residual
bitumen is equal to the values in this
table.
505.3.5. Compaction: After the spreading of

coarse aggregates, dry rolling shall be carried out
with an 8 - 10 tonne smooth steel wheel roller.
The requirements given in Clause 501.6 and
Page 372 of 1427

501.7 shall apply. After initial dry rolling, the
surface shall be checked with a crown template and a
3 metre straight-edge. The surface shall not vary
more than 10 mm from the template or straight-edge.
All surface irregularities exceeding the above limit
shall be corrected by removing or adding aggregates
as required.
The rolling shall continue until the
compacted coarse aggregate has a firm surface true
to the cross section shown on the plans and has a
texture that will allow free and uniform penetration
of the bituminous material.
505.3.6. Application of bituminous

material: After the coarse aggregate has been rolled
and checked, the bituminous binder shall be applied,
at the rate given in Table 500-6, in accordance with
Clause 501, and at a temperature directed by the
Engineer.
At the time of applying the binder, the
aggregates shall be surface dry for the full depth of
the layer.
In certain circumstances, depending on the
type and size of aggregate used, the Engineer may
direct the placing of a bed of clean sand or quarry
fines, not exceeding 10mm in thickness, on the
prepared foundation before placing the coarse
aggregate. The sand or fine material shall be slightly
wetted, just sufficient for it to slurry up during the
compaction process. Where cut back is used, if
flooding of the binder occurs it should be applied in
two operations, or as directed by the Engineer.
Page 373 of 1427

505.3.7. Application of key aggregates:
Immediately after the first application of bitumen,
the key aggregates, which shall be clean, dry, and
free from dust shall be spread uniformly over the
surface by means of an approved mechanical
spreader or by approved manual methods at the rate
Where directed by the Engineer, the surface
shall be swept and the quantity of key aggregate
adjusted to ensure uniform application, with all the
surface voids in the coarse aggregate being filled
without excess. The entire surface shall then be
rolled with a 8 - 10 tonnes smooth steel wheel roller
(or vibrating roller operating in non-vibratory mode)
in accordance with the procedure specified in Clause
505.3.5.

supplied and the works carried out the relevant
505.5. Surfacing
The Penetration Macadam shall be provided

with a surfacing (binder/ wearing course) within a
maximum of forty-eight hours. If there is to be any
delay, the penetration macadam shall be covered by
a seal coat to the requirements of Clause 513 before
Page 374 of 1427

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

Penetration Macadam base course shall be

measured as finished work in square metres.
505.8. Rate
The contract unit rate for Penetration

Macadam course shall be payment in full for
carrying out the required operations including, but
not necessarily limited to, all components listed in
Clause 501.8.2.(i) to (xi).
506. BUILT-UP SPRAY GROUT

506.1. Scope
This work shall consist of a two-layer

composite construction of compacted crushed coarse
aggregates with application of bituminous binder
after each layer, and with key aggregates placed on
top of the second layer, in accordance with the
requirements of these Specifications, to serve as a
Page 375 of 1427

base course and in conformity with the lines, grades
and cross-sections shown on the drawings or as
directed by the Engineer. The thickness of the course
shall be 75 mm.
Page 376 of 1427

Built-up spray grout shall be used in a single
course in a pavement structure.
506.2. Materials
506.2.1. Bitumen: Clause 504.2.1. shall

apply. Where permitted by the Engineer, an
appropriate grade of emulsion complying with IS
8887 may be used.
506.2.2. Aggregates: The coarse aggregate

shall conform to Clause 504.2.2.
The aggregate shall satisfy the physical
requirements set out in Table 500-3. The coarse and
key aggregates for built-up spray grout shall
conform to the grading given in Table 500-7.
REQUIREMENTS FOR
COARSE AND KEY
AGGREGATES FOR
BUILT-UP SPRAY GROUT
IS Sieve Cumulative per cent by weight of total aggregate passing

Designation (mm)
Coarse Aggregate Key Aggregate
53.0 100 --
26.5 40-75 --
22.4 -- 100
13.2 0-20 40-75
Page 377 of 1427

5.6 -- 0-20
2.8 0-5 0-5

506.3.2. Equipment: The provisions of

Clause 505.3.2 shall apply.
506.33. Preparation of base: The base on

which the built-up spray grout course is to be laid
shall be prepared, shaped and compacted to the
specified lines, grades and cross-sections in
accordance with Clauses 501 and 902 as appropriate.
A prime coat shall be applied in accordance with
Clause 502 with approved primer as directed by the
Engineer.
506.3.4. Tack coat: A tack coat shall be

applied in accordance with the procedure described
in Clause 503, as directed by the Engineer.
5063.5. Spreading and rolling coarse

aggregates for the first layer: Immediately after the
application of prime or tack coat, the clean, dry and
dust free coarse aggregates shall be spread uniformly
and evenly, by mechanical means, at the rate of 0.5
cu.m. per 10 sq.m. area.
Page 378 of 1427

Immediately after spreading of the
aggregates, the entire surface shall be rolled with an
8 - 10 tonnes smooth wheel steel roller. Rolling shall
commence at the edges and progress towards the
centre except in super-elevated and uni-directional
cambered portions where it shall proceed from the
lower edge to the higher edge. Each pass of the roller
shall uniformly overlap not less than one-third of the
track made in the preceding pass.
The surface of the layer shall be carefully
checked, after rolling, with a template and straight
edge and shall be within the tolerances specified, and
any deficiencies corrected by reworking and
recompacting the layer.
Care shall be taken not to over-compact the
layer.
506.3.6. Application of binder - first spray:

The binder shall be heated to the temperature
appropriate to the grade of bitumen approved by the
Engineer and sprayed on the aggregate at the rate of
15 kg/10 sq.m. (measured in terms of residual
bitumen content) at a uniform rate of spray by
mechanical sprayers capable of spraying bitumen
uniformly at the specified rates and temperatures.
Excessive deposits of binder caused by stopping or
starting of the sprayers or through leakage or for any
other reason shall be removed and made good.
506.3.7. Spreading and rolling of coarse

aggregate for the second layer: Immediately after
the first application of the binder, the second layer of
Page 379 of 1427

coarse aggregates shall be spread and rolled in
accordance with the procedure detailed in Clause
506.3.5.
506.3.8. Application of binder - second

spray: The second aggregate layer shall then be
sprayed with binder at the rate of 15 kg/10 sq. m.
(measured in terms of residual bitumen content) in
accordance with Clause 506.3.6.
506.3.9. Application of key aggregate:

Immediately after the second application of binder,
key aggregates shall be spread uniformly and evenly,
preferably by mechanical means, at the rate of 0.13
cu.m./10 sq.m. so as to cover the surface completely.
The key aggregate shall be clean, dry and free from
dust and deleterious matter. If necessary, the surface
shall be swept to ensure uniform application of the
key aggregates. The entire surface shall then be
rolled with an 8-10 tonnes smooth wheel steel roller
in accordance with Clause 506.3.5. While-rolling is
in progress, additional key aggregates, where
required, shall be spread by hand. Rolling shall
continue until the entire course is thoroughly
compacted and the key aggregates are firmly in
position.

conform to the requirements of Clause 902. All
materials shall comply with the requirements of the
Page 380 of 1427

relevant provisions in Section 900 of the
Specifications.
506.5. Final Surfacing
The built-up-spray-grout shall be provided

with final surfacing within a maximum of forty-eight
hours. If there is to be any delay, the course shall be
covered by a seal coat to the requirement of Clause
513 before it is open to traffic. Where the seal coat is
required as a result of the selected method of
performing this operation, then it shall be considered
incidental to the work and shall not be paid for
separately.
Page 381 of 1427


Built-up spray grout shall be measured as

506.8. Rate
The contract unit rate for built-up spray grout

operations as specified. The rate shall include for,
but not necessarily be limited to the components
listed in Clause 501.8.8.2. (i) to (xi).
507. DENSE GRADED BITUMINOUS

MACADAM
507.1. Scope
This clause specifies the construction of

Dense Graded Bituminous Macadam, (DBM), for
use mainly, but not exclusively, in base/binder and
profile corrective courses. DBM is also intended for
use as road base material. This work shall consist of
construction in a single or multiple layers of DBM
on a previously prepared base or sub-base. The
Page 382 of 1427

thickness of a single layer shall be 50mm to 100mm.
507.2. Materials

paving bitumen of Penetration Grade complying
with Indian Standard Specifications for “Paving
Bitumen” IS: 73, and of the penetration indicated in
Table 500-10 for dense bitumen macadam, or this
bitumen as modified by one of the methods specified
in Clause 521, or as otherwise specified in the
Contract. Guidance on the selection of an
appropriate grade of bitumen is given in The Manual
for Construction and Supervision of Bituminous
Works.

matter, organic or other deleterious substances.
Where the Contractor’s selected source of aggregates
have poor affinity for bitumen, as a condition for the
approval of that source, the bitumen shall be treated-
with an approved anti-stripping agent, as per the
payment. Before approval of the source, the
aggregates shall be tested for stripping. The
aggregates shall satisfy the physical requirements
specified in Table 500-8, for dense bituminous
macadam.
Page 383 of 1427

507.2.3. Fine aggregates: Fine aggregates

shall consist of crushed or naturally occurring
mineral material, or a combination of the two,
passing the 2.36mm sieve and
Page 384 of 1427

retained on the 75 micron sieve. They shall be clean,
hard, durable, dry and free from dust, and soft or
friable matter, organic or other deleterious matter.
The fine aggregate shall have a sand
equivalent value of not less than 50 when tested in
accordance with the requirement of 18:2720 (Part
37).
The plasticity index of the fraction passing

the 0.425 mm sieve shall not exceed 4. when tested
in accordance with IS: 2720 (Part 5)

REQUIREMENTS FOR COARSE
AGGREGATE FOB DENSE
GRADED BITUMINOUS
MACADAM
Property Test
Cleanliness(dust) Grain size analysis1 Max 5%
Particle shape Flakiness and Elongation Index M

(Combined)2
Strength* Los Angeles Abrasion Value3 M
Aggregate Impact Value4 M
Sodium Sulphate M
Magnesium Sulphate M
Water Water absorption6
Absorption
Stripping Coaling and Stripping of Bitumen Minimum
Aggregate Mixtures7
Page 385 of 1427

Water Retained Tensile Strength8
Sensitivity**
Notes : 1. IS : 2386 Part 1

5. IS : 2386 Part 5
2. IS : 2386 Part 1
6. IS : 2386 Part 3
(the elongation lest to be done only on non-
flaky aggregates in the sample)
3. IS: 2386 Part 4*
7. IS: 6241
4. IS: 2386 Part 4*
8. AASHTOT283**
* Aggregate may satisfy requirements
of either of these two tests.
** The water sensitivity test is only
required if the minimum retained
coating in the stripping test is less
than 95%.
507.2.4. Filler : Filler shall consist of finely

divided mineral matter such as rock dust, hydrated
lime or cement approved by the Engineer.
The filler shall be graded within the limits
indicated in Table 500-9.

FOR MINERAL FILLER
IS Sieve Cumulative per cent passing by

(mm) weight of total aggregate
Page 386 of 1427

0.6 100
0.3 95-100
0.075 85-100
Page 387 of 1427

The filler shall be free from organic
impurities and have a Plasticity Index not greater
than 4. The Plasticity Index requirement shall not
apply if filler is cement or lime. When the coarse
aggregate is gravel, 2 per cent by weight of total
aggregate, shall be Portland cement or hydrated lime
and the percentage of fine aggregate reduced
accordingly. Cement or hydrated lime is not required
when the limestone aggregate is used. Where the
aggregates fail to meet the requirements of the water
sensitivity test in Table 500-8, then 2 per cent by
total weight of aggregate, of hydrated lime shall be
added without additional cost.

content: When tested in accordance with IS:2386
Part 1 (wet sieving method), the combined grading
of the coarse and fine aggregates and added filler for
the particular mixture shall fall within the limits
shown in Table 500-10, for dense bituminous
macadam grading 1 or 2 as specified in the Contract.
The type and quantity of bitumen, and appropriate
thickness, are also indicated for each mixture type.

DENSE GRADED BITUMINOUS MACADAM
PAVEMENT LAYERS
Grading 1
Nominal aggregate size 40mm
Layer Thickness 80-100 mm 50
Page 388 of 1427

IS Sieve1 (mm) Cumulative % by weight of total ag
45 100
37.5 95-100
26.5 63-93
19 --
13.2 55-75
9.5 --
4.75 38-54
2.36 28-42
1.18 --
0.6 --
0.3 7-21
0.15 --
0.075 2-8
Bitumen content % by mass
of total mix2 Min4.0 M
Bitumen grade (pen) 65 or 90 6
Notes: 1. The combined aggregate grading dull
not vary from the low limit on one
sieve to the high limit on the adjacent
sieve.
2. Determined by the Marshall method.
5073. Mixture Design
5073.1. Requirement for the mixture:

Apart from conformity with the grading and quality
requirements for individual ingredient the mixture
shall meet the requirements set out in Table 500-11.
Page 389 of 1427

TABLE 500-11. REQUIREMENTS FOR
DENSE GRADED BITUMINOUS MACADAM
Minimum stability (kN at 9.0

60°C)
Minimum flow (mm) 2
Maximum flow (mm) 4
Compaction level 75 blows on each of the
(Number of blows) two
faces of the specimen
Per cent air voids 3-6
Percent voids in mineral See Table 500-12
aggregate (VMA) below.
Per cent voids filled with 65-75
bitumen (VFB)
The requirements for minimum per cent

voids in mineral aggregate (VMA) are set out in
Table 500-12.
TABLE 500-12. MINIMUM PER CENT

VOIDS IN MINERAL AGGREGATE
(VMA)
Nominal Maximum Minimum VMA, Per cent

Particle Size1 (mm) Related to
Design Air Voids, Per cent
3.0 4.0
9.5 14.0 15.0
125 13.0 14.0
19.0 12.0 13.0
25.0 11.0 12.0
Page 390 of 1427

37.5 10.0 11.0
Notes: 1. The nominal maximum particle size

is one size larger than the first sieve
to retain more than 10 per cent.
2. Interpolate minimum voids in the
mineral aggregate (VMA) for design
air voids values between those listed.
507.3.2. Binder content: The binder content

shall be optimised to achieve the requirements of the
mixture set out in Table 500-11 and the traffic
volume specified in the Contract. The Marshall
method for determining the optimum binder content
shall be adopted as described in The Asphalt
Institute Manual MS-2, replacing the aggregates
retained on the 26.5 mm sieve by the aggregates
passing the 26.5 mm sieve and retained on the 22.4
mm sieve, where approved by the Engineer.
Where 40 mm dense bituminous macadam
mixture is specified, the modified Marshall method
described in MS-2 shall be used. This method
requires modified equipment and procedures;
particularly the minimum stability values in Table
500-11 shall be multiplied by 2.25, and the minimum
flow shall be 3 mm.
507.3.3. Job mix formula: The Contractor

shall inform the Engineer in writing, at least 20 days
before the start of the work, of the job mix formula
proposed for use in the works, and shall give the
following details:
Page 391 of 1427

(i) Source and location of all materials:
(ii) Proportions of all materials expressed
as follows where each is applicable:
Page 392 of 1427

(a) Binder type, and percentage
by weight of total mixture;
(b) Coarse aggregate/Fine
aggregate/Mineral filler as
percentage by weight of total
aggregate including mineral
filler;
(iii) A single definite percentage passing
each sieve for the mixed aggregate:
(iv) The individual gradings of the
individual aggregate fractions, and
the proportion of each in the
combined grading.
(v) The results of tests enumerated in
Table 500-11 as obtained by the
Contractor;
(vi) Where the mixer is a batch mixer, the
individual weights of each type of
aggregate, and binder per batch.
(vii) Test results of physical characteristics
of aggregates to be used;
(viii) Mixing temperature and compacting
temperature.
While establishing the job mix formula, the

Contractor shall ensure that it is based on a correct
and truly representative sample of the materials that
will actually be used in the work and that the mixture
and its different ingredients satisfy the physical and
strength requirements of these Specifications.
Approval of the job mix formula shall be
based on independent testing by the Engineer for
Page 393 of 1427

which samples of all ingredients of the mix shall be
furnished by the Contractor as required by the
Engineer.
The approved job mix formula shall remain
effective unless and until a revised Job Mix Formula
is approved. Should a change in the source of
materials be proposed, a new job mix formula shall
be forwarded to the Engineer for approval before the
placing of the material.
507.3.4. Plant trials - permissible variation

in job mix formula:
Once the laboratory job mix formula is

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

FROM THE JOB MIX FORMULA
Description Permissible
Base/binder course
Aggregate passing 19nun sieve or larger ±8%
Aggregate passing 13.2mm, 9.5mm ±7%
Page 394 of 1427

Aggregate passing 4.75mm ±6%
Aggregate passing 2.36mm, 1.18mm, 0.6mm ±5%
Aggregate passing 0.3mm, 0. 15mm ±4%
Binder content ±0.3%
Mixing temperature ±10°C
Page 395 of 1427

Once the plant trials have demonstrated the
capability of the plant, and the trials are approved,
the laying operation may commence. Over the period
of the first month of production for laying on the
works, the Engineer shall require additional testing
of the product to establish the reliability and
consistency of the plant.
507.3.5. Laying Trials: Once the plant trials

have been successfully completed and approved, the
Contractor shall carry out laying trials, to
demonstrate that the proposed mix can be
successfully laid, and compacted all in accordance
with Clause 501. The laying trial shall be carried out
on a suitable area which is not to form part of the
works, unless specifically approved in writing, by
the Engineer. The area of the laying trials shall be a
minimum of 100 sq.m. of construction similar to that
of the project road, and it shall be in all respects,
particularly compaction, the same as the project
construction, on which the bituminous material is to
be laid.
The Contractor shall previously inform the
Engineer of the proposed method for laying and
compacting the material. The plant trials shall then
establish if the proposed laying plant, compaction
plant, and methodology is capable of producing
satisfactory results. The density of the finished
paving layer shall be determined by taking cores, no
sooner than 24 hours after laying, or by other
approved method.
Once the laying trials have been approved,
Page 396 of 1427

the same plant and methodology shall be applied to
the laying of the material on the project, and no
variation of either shall be acceptable, unless
approved in writing by the Engineer, who may at his
discretion require further laying trials.
507.4.1: Weather and seasonal limitations:

507.4.2. Preparation of base: The base on

which Dense Graded Bituminous Material is to be
laid shall be prepared in accordance with Clauses
501 and 902 as appropriate, or as directed by the
Engineer. The surface shall be thoroughly swept
clean by a mechanical broom, and the dust removed
by compressed air. In locations where-mechanical
broom cannot access, other approved methods shall
be used as directed by the Engineer.
507.4.3. Geosynthetics: Where

Geosynthetics are specified in the Contract this shall
be in accordance with the requirements stated in
Clause 703.
507.4.4. Stress absorbing layer: Where a

stress absorbing layer is specified in the Contract,
this shall be applied in accordance with the
507.4.5. Prime coat: Where the material on
Page 397 of 1427

which the dense bituminous macadam is to be laid is
other than a bitumen bound layer, a prime coat shall
be applied, as specified, in accordance with the
provisions of Clause 502, or as directed by the
Engineer.
507.4.6. Tack coat: Where the material on

which the dense bituminous macadam is to be placed
is a bitumen bound surface, a tack coat shall be
applied as specified, in accordance with the
provisions of Clause 503, or as directed by the
Engineer.
Page 398 of 1427

507.4.7. Mixing and transportation of the
mixture: The provisions as specified in Clauses
501.3 and 501.4 shall apply.

Clauses 501.5.3 and 501.5 4 shall apply.
507.4.9. Rolling: The general provisions of

Clauses SO 1.6 and 501 7 shall apply, as modified
by the approved laying trials. The compaction
process shall be carried out by the same plant, and
using the same method, as approved in the laying
trials, which may be varied only with the express
approval of the Engineer in writing.
The newly laid surface shall not be open to

traffic for at least 24 hrs after laying and completion
of compaction, without the express approval of the
Engineer in writing.

of Work

Clause 902. All materials and workmanship shall
comply with the provisions set out in Section 900 of
this Specification.
Page 399 of 1427

Dense Graded Bituminous Materials shall be

measured as finished work either in cubic metres,
tons or by the square metre at a specified thickness
as detailed on the Contract drawings, or documents,
507.9. Rate
The contract unit rate for Dense Graded

Bituminous Macadam shall be payment in full for
carrying out the all required operations as specified,
and shall include, but not necessarily limited to all
components listed in Clause 501.8.8.2 (i) to (xi). The
rate shall include the provision of bitumen, at 4.25
per cent by weight of the total mixture.
The variance in actual percentage of bitumen
used will be assessed and the payment adjusted, up
or down, accordingly.
508. SEMI-DENSE BITUMINOUS CONCRETE
508.1. Scope
This clause specifies the construction of Semi

Dense Bituminous Concrete, for use in
Page 400 of 1427

wearing/binder and profile corrective courses. This
work shall consist of construction in a single or
multiple layers of semi dense bituminous concrete
on a previously prepared bituminous bound surface.
A single layer shall be 25mm to 100mm in thickness.
Page 401 of 1427

508.2. Materials

paving bitumen of Penetration grade complying with
Indian Standard Specification for Paving Bitumen,
IS: 73 and of the penetration indicated in Table 500-
15, for semi dense bituminous concrete, or this
bitumen as modified by one of the methods specified
in Clause 521, or as otherwise specified in the
Contract. Guidance on the selection of an
appropriate grade of bitumen is given in The Manual
Works.

aggregates shall be generally as specified in Clause
507.2.2, except that the aggregates shall satisfy the
physical requirements of Table 500-14.
508.2.3. Fine aggregates: The fine

aggregates shall be all as specified in Clause 507.2.3.
508.2.4. Filler: Filler shall be generally as

specified in Clause 507.2.4. Where the aggregates
fail to meet the requirements of the water sensitivity
test in Table 500-14 then 2 per cent by total weight
of aggregate, of hydrated lime shall be added
without additional cost.

Part 1 (Wet sieving method), the combined grading
Page 402 of 1427

of the coarse and fine aggregates and added filler
shall fall, within the limits shown in table 500-15 for
gradings 1 or 2 as specified in the Contract.
508.3. Mixture Design
508.3.1. Requirements for the mixture:

requirements for individual ingredients the mixture
Page 403 of 1427

REQUIREMENTS FOR
COARSE AGGREGATE
FOR SEMI DENSE
BITUMINOUS
CONCRETE PAVEMENT
LAYERS
Property Test
Cleanliness (dust) Grain size analysis1 M
0
Panicle shape Flakiness and Elongation Index
(Combined)2
Strength* Los Angeles Abrasion Value3
Aggregate Impact Value4
Polishing Polished Stone Value5
Sodium Sulphate
Magnesium Sulphate
Stripping Coating and Stripping of Bitumen Min
Aggregate Mixtures9
Water Sensitivity** Retained Tensile Strength8
Notes: 1. IS: 2386 Part 1 6. IS:
Page 404 of 1427

2386 Part 5
2. IS: 2386 Part 1 7. IS:
2386 Part 3
(the elongation test may be done only on non-flaky
aggregates in the sample)
3. IS: 2386 Part 4* 8.
AASHTOT283**
4. IS: 2386 Part 4* 9. IS:
6241
5. BS: 812 Part 114
of cither of these two tests.
than 95%.
Table 500-12.

mixture set put in Table 500-16 and the traffic
volume as specified in the Contract. The Marshall
shall be adopted as described in the Asphalt Institute
Manual MS-2, replacing the aggregates retained on
the 26.5mm sieve and retained on the 22.4mm sieve,
where approved by the Engineer.
Page 405 of 1427

TABLE 500-45. COMPOSITION OF SEMI
DENSE BITUMINOUS CONCRETE
PAVEMENT LAYERS
Grading 1
Layer Thickness 35-40 mm
1
IS Sieve (mm) Cumulative % by weight of total agg
45
37.5
26.5
19 100
13.2 90-100
9.5 70-90
4.75 35-51
2.36 24-39
1.18 15-30
0.6 --
0.3 9-19
0.15 --
0.075 3-8
Bitumen content % by mass of
total mix3 Min 4.5
Bitumen grade (pen) 65*
Notes: 1. The combined aggregate grading shall
sieve.
* Only in exceptional circumstances,
80/100 penetration grade may be
used, as approved by the Engineer.
Page 406 of 1427

SEMI DENSE BITUMINOUS
PAVEMENT LAYERS

60°C)
Minimum flow (mm) 2
Maximum flow (mm) 4
Per cent voids in mineral See Table 500-12
aggregate (VMA)
bitumen (VFB)
508.3.3. Job mix formula: The procedure

for formulating the job mix formula shall be
generally as specified in Clause 507.3.3 and the
results of tests enumerated in Table 500-16 as
obtained by the Contractors.
Page 407 of 1427

5083.4. Plant trials - permissible variation
in job mix formula:
The requirements for plant trials shall be all
as specified in Clause 507.3.4. and permissible limits
for variation as shown in Table 500-13.
508.3.5. Laying trials: The requirements for

laying trials shall be all as specified in Clause
507.3.5.


on which the Semi Dense Bituminous material is to
be laid shall be prepared in accordance with Clauses
501 and 902 as appropriate, or as directed by the
Engineer. The surface shall be thoroughly swept
clean by mechanical broom and dust removed by
compressed air. In locations where a mechanical
broom cannot access, other approved methods shall
be used as directed by the Engineer.

Clause 703.
508.4.4. Stress absorbing layer: Where a

Page 408 of 1427

508.4.5. Tack coat: Where specified in the

Contract, or otherwise required by the Engineer, a
tack coat shall he applied in accordance with the

501.3.and 501.4 shall apply.
508.4.7. Spreading: The general provisions

of Clauses 501.5.3 and 501.5.4 shall apply.

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

traffic for at least 24 hours after laying and the
completion of compaction, without the express
Page 409 of 1427

this Specification.

The measurement shall be all as specified in

Clause 507.8.
508.9. Rate
The contract unit rate shall be all as specified

in Clause 507.9. except that the rate shall include the
provision of bitumen at 4.75 per cent, by weight of
total mixture. The variance in actual percentage of
bitumen used will be assessed and the payment
adjusted up or down, accordingly.
509. BITUMINOUS CONCRETE
509.1. Scope
This clause specifies the construction of

Bituminous Concrete, for use in wearing and profile
corrective courses. This work shall consist of
Page 410 of 1427

construction in a single or multiple layers of
bituminous concrete on a previously prepared
bituminous bound surface. A single layers shall be
25mm to 100mm in thickness.
509.2. Materials

paving bitumen of Penetration grade complying with
Indian Standard Specification for Paving Bitumen,
IS: 73 and of the penetration indicated in Table 500-
18. for bituminous concrete, or this bitumen as
modified by one of the methods specified in Clause
521, or as otherwise specified in the Contract.
Guidance on the selection of an appropriate grade of
bitumen is given in The Manual for Construction and
Supervision of Bituminous Works.

aggregates shall be generally as specified in Clause
507.2.2, except that the aggregates shall satisfy the
physical requirements of Table 500-17.
509.2.3. Fine aggregates: The fine

aggregates shall be all as specified in Clause 507.2.3.
509.2.4. Filler: Filler shall be generally as

specified in Clause 507.2.4. Where the aggregates
fail to meet the requirements of the water sensitivity
test in Table 500-17 then 2 per cent by total weight
of aggregate, of hydrated lime shall be added
without additional cost.
Page 411 of 1427

Part 1 (Wet grading method), the combined grading
of the coarse and fine aggregates and added filler
shall fall within the limits shown in Table 500-18 for
gradings 1 or 2 as specified in the Contract.
Page 412 of 1427


requirements for individual ingredients, the mixture
Table 500-12.

mixture set out in Table 500-19 and the traffic
volume as specified in the Contract. The Marshall
shall be adopted as described in the Asphalt Institute
Manual MS-2, replacing the aggregates retained on
the 26.5mrn sieve and retained on the 22.4mm sieve,
where approved by the Engineer.
509.3.3. Job mix formula: The procedure

for formulating the job
TABLE 500-17. PHYSICAL REQUIREMENTS

FOR COARSE AGGREGATE
FOR BITUMINOUS
CONCRETE PAVEMENT
LAYERS
Property Test
Cleanliness (dust) Grain size analysis1 M
Page 413 of 1427

0
Panicle shape Flakiness and Elongation Index
Strength* Los Angeles Abrasion Value3

Aggregate Impact Value4
Polishing Polished Stone Value5
Sodium Sulphate
Magnesium Sulphate
Stripping Coating and Stripping of Bitumen Min
Aggregate Mixtures9
Water Sensitivity** Retained Tensile Strength8
Notes: 1. IS: 2386 Part 1 6. IS:

2386 Part 5
2. IS: 2386 Part 1 7. IS:
2386 Part 3
(the elongation test may be done only on non-flaky
aggregates in the sample)
3. IS: 2386 Part 4* 8.
AASHTOT283**
4. IS: 2386 Part 4* 9. IS:
6241
5. BS: 812 Part 114
Page 414 of 1427

of cither of these two tests.
than 95%.
mix formula shall be generally as specified in Clause
507.3.3 and the results of tests enumerated in Table
500-19 as obtained by the Contractors.
509.3.4. Plant trials - permissible variation

in job mix formula:
The requirements for plant trials shall be all
as specified in Clause 507.3.4, and permissible limits
for variation as shown in Table 500-13.
509.3.5. Laying trials: The requirements for

laying trials shall be all as specified in Clause
507.3.5.


BITUMINOUS CONCRETE PAVEMENT
LAYERS
Grading 1
Layer Thickness 50-65 mm
Page 415 of 1427

IS Sieve1 (mm) Cumulative % by weight of total agg
45
37.5
26.5 100
19 79-100
13.2 59-79
9.5 52-72
4.75 35-55
2.36 28-44
1.18 20-34
0.6 15-27
0.3 10-20
0.15 5-13
0.075 2-8
Bitumen content % by mass of
5.0-6.0
total mix2
Bitumen grade (pen) 65
Notes: 1. The combined aggregate grading shall

sieve.
Page 416 of 1427

BITUMINOUS PAVEMENT LAYERS

60°C)
Minimum flow (mm) 2
Maximum flow (mm) 4
Per cent voids in mineral See Table 500-12
aggregate (VMA)
bitumen (VFB)
Loss of stability on Min. 75 per cent
immersion in water at
retained strength
60°C (ASTM D 1075)

on which the bituminous concrete is to be laid shall
be prepared in accordance with Clauses 501 and 902
as appropriate, or as directed by the Engineer. The
surface shall be thoroughly swept clean by
mechanical broom and dust removed by compressed
Page 417 of 1427

air. In locations where a mechanical broom cannot
access, other approved methods shall be used as

Clause 703.
509.4.4. Stress absorbing layer : Where a

509.4.5. Tack coat: Where specified in the

Contract, or otherwise required by the Engineer, a
tack coat shall be applied in accordance with the

501.3 and 501.4 shall apply.
509.4.7. Spreading: The general provisions

of clauses 501.5.3 and 501.5.4 shall apply.

clauses 501.6 and 501.7 shall apply, as modified by
the approved laying trials.
Page 418 of 1427

traffic for at least 24 hours after laying and the
completion of compaction, without the express
Page 419 of 1427


this Specification.

with the provisions of Clause 112
The measurement shall be all as specified in

Clause 507.8.
509.9. Rate
The contract unit rate shall be all as specified

in Clause 507.9, except that the rate shall include the
provision of bitumen at 5.0 per cent, by weight of
total mixture. The variance in actual percentage of
bitumen used will be assessed and the payment
adjusted up or down, accordingly.
510. SURFACE DRESSING
510.1. Scope
Page 420 of 1427

This work shall consist of the application of
one coat or two coats of surface dressing, each coat
consisting of a layer of bituminous binder sprayed on
a previously prepared base, followed by a cover of
stone chips rolled in to form a wearing course to the
requirements of these Specifications. For
information on the Design of Surface Dressing refer
to the Manual for Construction and Supervision of
Bituminous Works
510.2. Materials
510.2.1. Binder: The binder shall have a

kinematic viscosity lying in the range 1x104 to 7x10s
centistokes at the expected range of road surface
temperatures at the construction site during the
period of laying. The type of binder to be used will
be stated in the Contract documents and shall
comply with one of the following:
Paving Bitumen IS:73
Bitumen Emulsion IS:8887
510.2.2. Aggregates: The chips shall

conform to the requirements of Clause 504.2.2.
except that their water absorption shall be restricted
to a maximum of 1 per cent and they shall have a
Polished Stone value, as measured by the method
given in BS812 (Part 114), of not less than 60. The
chips shall be single sized, clean, hard, durable, of
Page 421 of 1427

matter, organic or other deleterious matter and
conforming to one of the gradings given in Table
500-21.
Page 422 of 1427

510.2.3. Rates of spread of binder and
chips: For the purpose of pricing the Bill of
Quantities the rates of spread given in Table 500-20
shall be priced.
TABLE 500-20. NOMINAL RATES OF

SPREAD FOR BINDER AND
CHIPPINGS (1)
Nominal Chipping Binder (penetration grade

Size mm bitumen ) kg/m2
19 1.2
13 1.0
10 0.9
6 0.75
Note: (1) These rates of spread are for pricing
purposes - see Clause 510.2.3 and
Clause 510.8
(2) For emulsion, these rates of spread
are for the residual bitumen and
appropriate adjustment must be made
to determine the total quantity.
(3) Refer to Manual for Construction and
Supervision of Bituminous Works for
the procedure of determining the rates
of spread of hinder and chips.
510.2.4. Anti-stripping agent: Where the

proposed aggregate fails to pass the stripping test
Page 423 of 1427

then an approved adhesion agent (Appendix 5 for
details) may be added to the binder in accordance
with the manufacturer’s instructions. The
effectiveness of the proposed anti-stripping agent
must be demonstrated by the Contractor, before
approval by the Engineer.
510.2.5. Pre-coated chips: As an alternative

to the use of an adhesion agent the chips may be pre-
coated before they are spread except when the
sprayed binder film is a bitumen emulsion. Pre-
coating the chips may be carried out in any one of
the two methods:
(a) Mixing them with 0.75 to 1.0 per cent
of paving bitumen by weight of chips
in a suitable mixer, the chips being
heated to 160°C and the bitumen to
its application temperature. The pre-
coated chips shall be allowed to cure
for at least one week or until they
become non sticky and can be spread
easily.
(b) Spraying the chips with a light
application of creosote, diesel oil or
kerosene at ambient temperature. This
spraying can be done in a concrete
mixer or on a belt conveying the
chips from stockpile to gritting
lorries.
510.3. Construction operations
Page 424 of 1427

510.3.1. Weather and seasonal limitations :
Page 425 of 1427

FOR CH1FS FOR
SURFACE DRESSING
IS Sieve Cumulative per cent by weight of total aggregate

Designation following nominal sizes (mm)
mm
19 13 10
26.5 100 -- --
19.0 85-100 100 --
13.2 0-40 85-100 100
9.5 0-7 0-40 85-100
6.3 -- 0-7 0-35
4.75 -- -- 0-10
3.35 -- -- --
2.36 0-2 0-2 0-2
0.60 -- -- --
0.075 0-1.5 0-1.5 0-1.5
Minimum Passing 19 mm, Passing 13.2 mm, Passing 9.5 m
65% by retained 13.2 mm retained 9.5 mm retained 6.3 m
weight of
aggregate

which the surface dressing is to be laid shall be
prepared, shaped and conditioned to the specified
lines, grade and cross section in accordance with
Clause 501 or as directed by the Engineer. Prime
coat, where needed, shall be provided as per Clause
502 or as directed by the Engineer. Where the
existing surface shows signs of fatting up, the excess
Page 426 of 1427

bitumen shall be removed by burning off, or
manually, as specified in the Contract or directed by
the Engineer. The bituminous surface to be dressed
shall be thoroughly cleaned either by using a
mechanical broom and/or compressed air, or any
other approved equipment method as specified in the
Contract or by the Engineer. The prepared surface
shall be dust free, clean and dry, (except in the case
of cationic emulsion where the surface shall be
damp).
510.3.3. Application of binder : The

equipment and general procedures shall all be in
accordance with the Manual for Construction and
Supervision of Bituminous Works. The application
temperature for the grade of binder used shall be as
given in Table 500-22 and the rate of spray as given
in 510.2.3.
5103.4. Application of stone chips : The
equipment and general
Page 427 of 1427

TABLE 500-22. SPRAYING
TEMPERATURES FOR BINDERS
Binder grades Whirling Slot

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

Works. For relatively small areas of surface
dressing, careful application of chips by hand may
be acceptable if approved by the Engineer. The rate
of application of chips shall be as determined by the
procedure given in the Manual for Construction and
Supervision of Bituminous Works. Immediately after
application of the binder, clean, dry chips (in the
case of emulsion binder the chippings may be damp)
shall be spread uniformly on the surface so as to
cover the surface completely with a single layer of
chips.
510.3.5. Rolling: Rolling of the chips should

preferably be carried out by a pneumatic tyred roller
Page 428 of 1427

in accordance with Clause 501.6 and Clause 501.7.
Traditional steel wheeled rollers tend to crush the
aggregates and if their use cannot be avoided their
weight should be limited to 8 tonnes. Rolling shall
commence at the edges and progress towards the
centre except in superelevated and uni-directional
cambered portions where it shall proceed from the
lower edge to the higher edge. Each pass of the roller
shall uniformly overlap not less than one-third of the
track made in the preceding pass. While rolling is in
progress additional chips shall be spread by hand in
necessary quantities required to make up
irregularities. Rolling shall continue until all
aggregate particles are firmly embedded in the
binder and present a uniform closed surface.
5103.6. Application of second coat of

surface dressing : Where surface dressing in two
coats is specified, the second coat should not be
applied until the first coat has been open to traffic for
2 or 3 weeks. The surface on which the second coat
is laid must be clean and free of dust. The
construction operations for the second coat shall be
the same as described in Clauses 510.3.3 to 510.3.5.
Traffic shall not be permitted to run on any

newly surface dressed area until the following day.
In special circumstances, however, the Engineer may
allow the road to be opened to traffic immediately
after rolling, but in such cases traffic speed shall be
Page 429 of 1427

limited to 20 km per hour until the following day.
Page 430 of 1427

Control of Work

For control on the quality of materials

Each coat of surface dressing shall be

measured as finished work, for the area instructed to
be covered, in square metres.
510.8. Rate
The Contract unit rate for surface dressing,

based on the notional rates of spread for binder and
each size of chippings given in Clause 5 10.2.3,
which shall be adjusted, plus or minus, for the
difference between the notional rates of spread and
the rates of spread determined as described in the
Manual for Construction and Supervision of
Bituminous Works, and approved by the Engineer,
multiplied by the rates entered in the Bill of
Page 431 of 1427

Quantities for binder and each size of chipping. The
adjusted rate shall be payment in full for carrying out
for all components listed in Clause 501.8.8.2. (i) to
(xi).
511. OPEN-GRADED PREMIX

SURFACING
511.1. Open-graded Premix Surfacing using

Penetration Bitumen or Cutback.

the preparation, laying and compaction of an open-
graded premix surfacing material of 20 mm
thickness composed of small-sized aggregate
premixed with a bituminous binder on a previously
prepared base, in accordance with the requirements
of these Specifications, to serve as a wearing course.
511.1.2. Materials
511.1.2.1. Binder: The binder shall be a

penetration bitumen of a suitable grade as specified
in the Contract, or as directed by the Engineer, and
satisfying the requirements of IS: 73.
511.1.2.2. Aggregate : The aggregate shall

conform to Clause 504.2.2 except that the water
absorption shall be limited to a maximum of 1 per
cent. The Polished Stone Value, as measured by the
test in BS 812- (Part 114), shall not be less than 55.
Page 432 of 1427

511.1.2.3. Proportioning of materials: The
materials shall be proportioned in accordance with
Table 500-23.
Page 433 of 1427

511.1.3. Construction operations
511.1.3.1. Weather and seasonal

limitations : Clause 501.5.1 shall apply.
511.1.3.2. Preparation of surface: The

underlying surface on which the bituminous
surfacing is to be laid shall be prepared, shaped and
conditioned to the specified lines, grade and cross-
section in accordance with Clause 501. A prime coat
where needed shall be applied in
TABLE 500-23. QUANTITIES OF

MATERIALS REQUIRED
FOR 10m2 OF ROAD
SURFACE FOR 20mm
THICK OPEN-GRADED
PREMIX SURFACING
USING PENETRATION
BITUMEN OR CUTBACK
Page 434 of 1427

Aggregates
(a) Nominal Stone size 13.2mm (passing 22.4
mm 0.18m3
sieve and retained on 11.2 mm sieve )
(b) Nominal Stone size 11.2mm (passing 13.2
mm 0.09m3
sieve and retained on 5.6 mm sieve ).
Total
0.27m3
Binder (quantities in terms of straight run bitumen)
(a) For 0.18 m3 of 13.2 mm nominal size stone
9.5 kg
at 52 kg bitumen per m3
(b) For 9.09m’of 11.2 mm nominal size stone
5.1kg
at 56 kg bitumen per m3
Total
14.6kg
accordance with Clause 502 as directed by the

Engineer.
511.1.3.3. Tack coat: A tack coat complying

with Clause 503, shall be applied over the base
Page 435 of 1427

preparatory to laying of the surfacing.
511.1.3.4. Preparation of premix : Hot mix

plant of appropriate capacity and type shall be used
for the preparation of the mix material. The hot mix
plant shall have separate dryer arrangement for
heating aggregate.
The temperature of the binder at the time of
mixing shall be in the range of 1500C to 163°C and
that of the aggregate in the range of 1550C to 1630C
provided that the difference in temperature between
the binder and aggregate at no time exceeds 140C.
Mixing shall be thorough to ensure that a
homogeneous mixture is obtained in which all
particles of the aggregates are coated uniformly and
the discharge temperature of mix shall be between
130°C and 160°C.
The mix shall be immediately transported
from the mixer to the point of use in suitable
vehicles or hand barrows. The vehicles employed for
transport shall be clean and the mix being
transported covered in transit if so directed by the
Engineer,
Page 436 of 1427

511.1.3.5. Spreading and rolling : The pre
mixed material shall be spread by suitable means to
the desired thickness, grades and cross-full (camber)
making due allowance for any extra quantity
required to fill up depressions, if any. The cross-fall
should be checked by means of camber boards and
irregularities levelled out. Excessive use of blades or
rakes should be avoided. As soon as sufficient length
of bituminous material has been laid, rolling shall
commence with 8 – 10 tonne rollers, - smooth wheel
tandem type, or other approved equipment. Rolling
shall begin at the edge and progress toward the
center longitudinally, except that on superelevated
and uni-directional cambered portions, it shall
progress from the lower to upper edge parallel to the
centre line of the pavement.
When the roller has passed over the whole
area once, any high spots or depressions, which
become apparent, shall be corrected by removing or
adding premixed materials. Rolling shall then be
continued until the entire surface has been rolled and
all the roller marks eliminated. In each pass of the
roller the preceding track shall be overlapped
uniformly by at least 1/3 width. The roller wheels
shall be kept damp to prevent the premix from
adhering to the wheels. In no case shall
fuel/lubricating oil be used for this purpose. Excess
use of water for this purpose shall also be avoided.
Rollers shall not stand on newly laid
material. Rolling operations shall be completed in
every respect before the temperature of the mix falls
below 100° C. Joints along and transverse to the
Page 437 of 1427

surfacing laid and compacted earlier shall be cut
vertically to their full depth so as to expose fresh
surface which shall be painted with a thin coat of
appropriate.1 hinder before the new mix is placed
against it.
511.1.3.6. Seal coat : A seal coat conforming

to Clause 513 of the type specified in the Contract
shall be applied to the surface immediately after
laying the surfacing.
511.1.4. Opening to traffic : No traffic shall

be allowed on the road until the seal coat has been
laid. After the seal coat is laid, the road may be
opened to traffic according to Clause 513.4.

of work : The surface finish of construction shall
conform to the requirements of Clause 902. For
control of the quality of materials supplied and the
works carried out, the relevant provisions of Section
900 shall apply.
511.1.6. Arrangements for traffic : During

the period of construction, arrangement of traffic
Clause 112.
511.1.7. Measurement for payment: Open

graded premix surfacing shall be measured as
finished work, for the area instructed to be covered,
in square metres. The area will be the net area
Page 438 of 1427

covered, and all allowance for wastage and cutting
of joints shall be deemed to be included in the rate.
511.1.8. Rate : The contract unit rate for

open-graded premix surfacing shall be payment in
listed in Clause 501.8.8.2. (i)to(xi).
511.2. Open graded premix surfacing

using cationic bitumen emulsion

the preparation, laying and compaction
Page 439 of 1427

of an open graded premix surfacing of 20 mm
thickness composed of small-sized aggregate
premixed with a cationic bitumen emulsion on a
previously prepared surface, in accordance with the
requirements of these Specifications, to serve as a
wearing course.
511.2.2. Materials
511.2.2.1. Binder : The binder for Premix

wearing course shall be cationic bitumen emulsion
of Medium Setting (MS) grade complying with I.S.
8887 and having a bitumen content 65 per cent
minimum by weight. For liquid seal coat RS grade of
Cationic bitumen emulsion shall be used. Where
expressly specified in the Contract MS grade
emulsion shall be used or otherwise directed by the
Engineer. Slow Setting (SS) grade Cationic bitumen
Emulsion shall be used for premix seal coat.
511.2.2.2. Aggregate : The requirements of

Clause 51 1.1.2.2. shall apply.
511.2.3. Proportioning of materials: The

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

AGGREGATE FOR 10 M2 AREA
Page 440 of 1427

(A) Premix Carpet
(a) Coarse aggregate nominal 13.2 mm size;
passing IS 22.4 mm
sieve and retained on IS 11.2 mm sieve
0.18m3
(b) Coarse aggregate nominal 11.2 mm size;
passing I.S 13.2 mm
sieve and retained on IS 5.6 mm sieve
0.09m3
(B) For Seal Coat:
Refer to Clause 5 13.

EMULSION BINDER
For 10m2 area

(A) For Premix Carpet:
20 to 23 kg.
(B) For Seal Coat:
(a) for liquid seal coat
12 to 14 kg.
Page 441 of 1427

(b) for premix seal coat
10 to 12 kg.
511.2:4.1. Weather and seasonal

limitations: Clause 501.5.1 shall apply except that
the minimum air temperature for laying shall be
10°C. Cationic bitumen emulsions shall not normally
be stored below 0°C.
511.2.4.2. Preparation of surface: The
underlying surface on which the premix surfacing is
to be laid shall be prepared, in accordance with the
requirements of Clause 504.3.2 for a newly primed
surface, and in accordance with Clause 507.4.2
where an
Page 442 of 1427

existing bituminous surface is to be overlaid.
511.2.4.3. Preparation of binder : Before

opening, the cationic bitumen emulsion drums shall
be rolled at slow speed, to and fro, at least 5 times,
for a distance of about 10 metres, to distribute any
storage sedimentation.
511.2.4.4. Tack coat: A tack coat complying

with Clause 503, shall be applied over the surface
preparatory to laying of the surfacing where
specified in the Contract, or directed by the
Engineer.
511.2.4.5. Preparation of premix :

Premixing of cationic bitumen emulsion and
aggregates can be carried out in a suitable mixer
such as cold mixing plant as per IS: 5435 (Revised)
or concrete mixer or by pay loaders in exceptional
cases where approved by the Engineer. Where
specified in the Contract continuous mixing
operation shall be done either in batch or continuous
hot mix plant suitable for emulsion mixes.
When using concrete mixer for preparing the
premix, 0.135 cu.m. (0.09 cu.m. of 13.2 mm size and
0.045 cu.m. of 11.2 mm size) of aggregates per batch
shall be used which quantity will cover 5 sq.m. of
road surface with 20 mm average thickness.
The aggregates required for one batch shall
be prepared adjacent to the mixer.
First the coarse aggregate of 13.2 mm size
shall be placed into the mixer followed by 5 to 6.5
Page 443 of 1427

kg of Cationic bitumen emulsion and then the 11.2
mm size aggregate shall be added, followed by 5 to
6.5 kg of Cationic bitumen emulsion. After the
materials have been mixed thoroughly, the mix shall
be immediately transported to the laying site in
suitable vehicles. Too much mixing shall be avoided.
When mixed manually by shovels, with the
approval of the Engineer, 0.06 cu.m. of aggregates
can be conveniently mixed in one heap, with
appropriate quantity of emulsion. It is preferable to
make the aggregates damp before mixing as it
reduces the effort required for mixing and also helps
to get better coating of aggregates. The 13.2 nun size
aggregates and emulsion are mixed first and then the
11.2 mm size aggregates and remaining quantity of
emulsion are added and mixed. Too much mixing
shall be avoided.
511.2.4.6. Spreading and rolling: The

premixed cationic bitumen emulsion and aggregates
shall be spread within 10 minutes of applying the
tack coat. All levelling, raking, etc. should be
completed within 20 minutes of the time of mixing.
The mix should be spread uniformly to the
desired thickness, grades and crossfall (camber)
making due allowance for any extra quantity
required to fill up depressions, if any. The crossfall
should be checked by means of camber boards and
irregularities leveled out. Too much raking is to be
avoided.
The rolling shall start immediately after
laying the premix. A smooth wheeled tandem roller
Page 444 of 1427

of 8-10 tonnes shall be used, unless other
compaction methods are approved by the Engineer,
based on the results of laying trials, if necessary.
While rolling, wheels of roller should be clean and
kept moist to prevent the premix from adhering to
the wheels. In no case shall fuel / lubricating oil be
used for this purpose. Use of water for this purpose
shall be strictly limited to an absolute minimum.
Rolling shall commence at the edges and
progress towards the centre longitudinally except in
the case of supereievated and uni-directional
cambered sections where rolling shall be carried out
from the lower edge towards the higher edge parallel
to the centre line of the road.
After one pass of roller over the whole area,
depressions or uncovered spots should be corrected
by adding premix material. Rolling shall be
continued until the entire
Page 445 of 1427

surface has been rolled to maximum compaction and
all the roller marks eliminated. In each pass of the
roller the preceding track shall be overlapped
uniformly by at least 1/3 width. Roller(s) shall not
stand on newly laid material. Joints both longitudinal
and transverse to the road sections laid and
compacted earlier, shall be cut vertically to their full
depth so as to expose fresh surface which shall be
painted with a thin surface coat of binder before the
new mix is placed against it.
511.2.4.7. Seal coat: A seal coat, conforming

to Clause 510 or Clause 513, as specified in the
Contract, shall be applied 4 to 6 hours after laying
the premix carpet.
511.2.5. Opening to traffic : Traffic should

not be allowed over the premix surface with or
without seal coat, for 6 to 8 hours after rolling, in
case of single lane roads, traffic shall be allowed
onto the surface once it has reached ambient
temperature, but speed must be rigorously restricted
to not more than 16 km per hour. If any premix
material is picked up by vehicle tyres, the spot shall
be filled up by new mix. If traffic conditions permit,
the road shall not be opened until a full 24 hours
after laying.

: The surface finish of construction shall conform to
the requirements of Clause 902.
Page 446 of 1427

511.2.7. Arrangements for traffic : During

the period of construction, arrangements for traffic
Clause 112.
511.2.8. Measurement for payment : Open

graded premix carpet shall be measured as finished
work, for the area specified to be covered, in square
metres at the specified thickness, in cubic metres, or
in tonnes weight as specified in the Contract. The
area will be the net area covered, and all allowances
for wastage and cutting of joints shall be deemed to
be included in the rate.

premix carpet and seal coat shall be payment in full
for carrying out the required operations incluuing
full compensation for all components listed in
Clause 501.8.8.2. (i) to (xi).
Bitumen quantities are to be as stated in
Table 500-23 for premix, 3.0 Kg per 10 sq.m., for
tack coat, 13Kg per 10 sq.m. for liquid seal coat and.
11 Kg per 10 sq.m. for premix seal coat. The rate
will be adjusted according to actual material used.
512. CLOSE-GRADED PREMIX SURFACING/

MIXED SEAL SURFACING
512.1. Scope
Page 447 of 1427

512.1.1. This work shall consist of the
preparation, laying and compaction of a close-graded
premix surfacing material of 20 mm thickness
composed of graded aggregates premixed with a
bituminous binder on a previously prepared surface,
in accordance with the requirements of these
Specifications, to serve as a wearing course.
512.1.2. Close graded premix surfacing shall

be of Type A or Type B as specified in the Contract
documents.
Page 448 of 1427

512.2. Materials
512.2.1. Binder : The provisions of Clause

511.1.2.1 shall apply
512.2.2. Coarse aggregates : The provisions

of Clause 511.1.2.2 shall apply.
512.2.3. Fine aggregates : The fine

aggregates shall consist of crushed rock quarry
sands, natural gravel / sand or a mixture of both.
These shall be clean, hard, durable, un-coated,
mineral particles, dry and free from injurious, soft or
flaky particles and organic or deleterious substances.
512.2.4. Aggregate gradation: The coarse

and fine aggregates shall be so graded or combined
as to conform to one or the other gradings shown in
Table 500-26, as specified in the contract.
TABLE 500-26. AGGREGATE GRADATION

IS Sieve Designation Cumulative per total weight of
(mm) total aggregate passing
Type A Type B
13.2mm -- 100
11.2mm 100 88-100
5.6mm 52-88 31-52
2.8mm 14-38 5-25
Page 449 of 1427

0.090 mm 0-5 0-5
512.2.5. Proportioning of materials: The

total quantity of aggregates used for Type A or B
close-graded premix surfacing shall be 0.27 cubic
metre per 10 square metre area. The quantity of
binder used for premixing in terms of straight-run
bitumen shall be 22.0 kg and 19.0 kg per 10 square
metre area for Type A and Type B surfacing
respectively.
The provisions of Clause 511.1.3.1 through

511.1.3.5 shall apply.
Traffic may be allowed after completion of

the final rolling when the mix has cooled down to
the surrounding temperature. Excessive traffic
speeds should not be permitted.

of Work

control on the quality of materials supplied and the
900 shall apply.
Page 450 of 1427


arrangements for traffic shall be in accordance with
the provisions of Clause 112.
Close-graded premix surfacing, Type A or B

shall be measured as finished work, for the area
specified to be covered, in square metres at a
specified thickness. The area will be the net area
covered, and all allowances for wastage and cutting
of joints shall be deemed to be included in the rate.
512.8. Rate
The contract unit rate for close-graded

premix surfacing, Type A or B shall be payment in
513. SEAL COAT

513.1. Scope
513.1.1. This work shall consist of the

application of a seal coat for sealing the voids in a
bituminous surface laid to the specified levels^ grade
and cross fall (camber).
513.1.2. Seal coat shall be of either of the
Page 451 of 1427

two types specified below:
(A) Liquid seal coal comprising of an

application of a layer of bituminous
binder followed by a cover of stone
chips.
(B) Premixed seal coat comprising of a
thin application of fine aggregate
premixed with bituminous binder.
513.2. Materials
513.2.1. Binder: The requirements of

Clauses 511.1.2.1 and 511.2.2.1. shall apply.
The quantity of bitumen per 10 square
metres, shall be 9.8 kg for Type A, and 6.8 kg for
Type B seal coat. Where bituminous emulsion is
used as a binder the quantities for Type A and Type
B seal coats shall be 15 Kg and 10.5 Kg respectively.
513.2.2. Stone chips for Type A seal coat :

The stone chips shall consist of angular fragments of
clean, hard, tough and durable rock of uniform
quality throughout. They should be free of soft or
disintegrated stone, organic or other deleterious
matter. Stone chips shall be of 6.7mm size defined as
100 per cent passing through 11.2 mm sieve and
retained on 2.36 mm sieve. The quantity used for
spreading shall be 0.09 cubic metre per 10 square
metre area. The chips shall satisfy the quality
requirements in Table 500-3 except that the upper
limit for water absorption value shall be 1 per cent.
Page 452 of 1427

513.2.3. Aggregate for Type B seal coat :
The aggregate shall be sand or grit and shall consist
of clean, hard, durable, uncoated dry particles and
shall be free from dust, soft or flaky / elongated
material, organic matter or other deleterious
substances. The
Page 453 of 1427

aggregate shall pass 2.36mm sieve and be retained
on 180 micron sieve. The quantity used for
premixing shall be 0.06 cubic metres per 10 square
metres area.

The requirements of Clause 501.5.1 shall apply.
513.3.2. Preparation of surface : The seal

coat shall be applied immediately after laying the
bituminous course which is required to be sealed.
Before application of seal coat materials, the surface
shall be cleaned free of any dust or other extraneous
matter.
513.3.3. Construction of Type A seal coat:

Bitumen shall be heated to 150°C-163°C and
sprayed at the rate specified on the dry surface in a
uniform manner with a self-propelled mechanical
sprayer as described in the Manual for Construction
and Supervision of Bituminous Works.
Immediately after the application of binder,
stone chips, which shall be clean and dry, shall be
spread uniformly at the rate specified on the surface
preferably by means of a self-propelled or towed
mechanical grit spreader so as to cover the surface
completely. If necessary, the surface shall be
brushed to ensure uniform spread of chips.
Immediately after the application of the cover
material, the entire surface shall be rolled with a 8 -
Page 454 of 1427

10 tonne smooth wheeled steel roller, 8 - 10 tonne
static weight vibratory roller, or other equipment
approved by the Engineer after laying trials if
required. Rolling shall commence at the edges and
progress towards the centre except in superelevated
and unidirectional cambered portions where it shall
proceed from the lower edge to the higher edge.
Each pass of the roller shall uniformly overlap not
less than one-third of the track made in the preceding
pass. While rolling is in progress, additional chips
shall be spread by hand in necessary quantities
required to make up irregularities. Rolling shall
continue until all aggregate particles are firmly
embedded in the binder and present a uniform closed
surface.
513.3.4. Construction of Type B seal coat:

A mixer of appropriate capacity and type approved
by the Engineer shall be used for preparation of the
mixed material. The plant shall have separate dryer
arrangements for heating aggregate.
The binder shall be heated in boilers of
suitable design, approved by the Engineer to the
temperature appropriate to the grade of bitumen or as
directed by the Engineer. The aggregates shall be dry
and suitably heated to a temperature between 150°C
and 165°C or as directed by the Engineer before
these components are placed in the mixer. Mixing of
binder with aggregates to the specified proportions
shall be continued untill the latter are thoroughly
coated with the former.
The mix shall be immediately transported
Page 455 of 1427

from the mixing plant to the point of use and spread
uniformly on the bituminous surface to be sealed.
As soon as a sufficient length has been
covered with the premixed material, the surface shall
be rolled with an 8-10 tonne smooth-wheeled roller.
Rolling shall be continued until the premixed
material completely seals the voids in the bituminous
course and a smooth uniform surface is obtained.
Page 456 of 1427

In the case of Type B seal coat, traffic may

be allowed soon after final rolling when the
premixed material has cooled down to the
surrounding temperature. In the case of Type A seal
coat, traffic shall not be permitted to run on any
newly sealed area until the following day. In special
circumstances, however, the Engineer may open the
road to traffic immediately after rolling, but in such
cases traffic speed shall be rigorously limited to 16
km per hour until the following day.

of Work
The surface finis} of construction shall


Seal coat, Type A or B shall be measured as

finished work, over the area specified to be covered,
Page 457 of 1427

in square metres at the thickness specified in the
Contract.
513.8. Rate
The contract unit rate for seal coat Type A or

B shall be payment in fail for carrying out the
all components listed in Clause 501.8.8.2. (i) to (xi).
514. SUPPLY OF STONE AGGREGATES FOR

PAVEMENT COURSES
514.1. Scope
This Specification Clause shall apply to the

supply of stone aggregates only. The work shall
consist only of collection, transportation and
stacking the stone aggregates and stone filler for
subsequent use in pavement courses. The actual
work of laying the pavement courses shall, however,
be governed by the individual Specification Clause
for the actual work, given elsewhere in this
Specification. The size and quantities of the
aggregates to be supplied shall be so selected by the
Engineer that the grading requirements set forth in
the individual Specification Clauses for the
pavement courses, for which the supply is intended,
are satisfied.
All the materials shall be procured from
approved sources and shall conform to the physical
requirements, specified in the respective
Specification Clauses for the individual items given
Page 458 of 1427

elsewhere in this Specification.
Page 459 of 1427

514.2. Sizes of Stone Aggregates
The stone aggregates shall be designated by

their standard sizes in the Contract and shall conform
to the requirements shown in Table 500-27.
TABLE 500-27. SIZE REQUIREMENTS FOR

COARSE STONE AGGREGATES
S.No. Nominal size of Designation of sieve Desig

aggregate through which the which t
aggregates shall wholly pass be
(i) 75 mm 106 mm
(ii) 63 mm 90 mm
(iii) 45 mm 53 mm
(iv) 26.5 mm 45 mm
(v) 22.4 mm 26.5 mm
(vi) 13. 2 mm 22.4 mm
(vii) 11.2 mm 13.2 mm
(viii) 6.7 mm 11.2 mm
514.3. Stacking
1. Coarse Aggregates:
Only the aggregates satisfying the
Page 460 of 1427

Specification requirements shall be conveyed to the
roadside and stacked. Each size of aggregate shall be
stacked separately. Likewise, materials obtained
from different quarry sources shall be stacked
separately and in such a manner that there is no
contamination of one source with another.
2. Fine Aggregate: As stated in the

individual relevant Specification Clauses.
The aggregates shall be stacked entirely clear

of the roadway on even clear hard ground, or on a
platform prepared in advance for the purpose by the
Contractor at his own cost and in a manner that
allows correct and ready measurement. If the
stockpile is placed on ground where the scraping
action of the loader can contaminate the material
with underlying soil, then the stockpile shall be
rejected by the Engineer. Materials shall not be
stacked in locations liable to inundation or flooding.
The dimensions of the stockpiles and their
location shall be approved by the Engineer. Where
the material is improperly stacked, the Engineer shall
direct complete re-stacking of the materials in an
approved manner at the Contractor’s cost.
Stone filler shall be supplied in a dry state in
bags or other suitable containers approved by the
Engineer and shall be protected from the
environment, so as to prevent deterioration in
quality.
Page 461 of 1427

514.4. Quality Control of Materials
The Engineer shall exercise control over the

quality of the materials so as to ascertain their
conformity with the Specification requirements, by
carrying out tests for the specified properties.
Testing shall be to the following frequencies
and the Engineer may, at his discretion, direct these
to be modified according to requirements:
Coarse and fine: One test for each
specified property per 50 m3 of stone
aggregates.
Stone filler: One test for each
specified property for
every five tonnes,
subject to a minimum
of one test for each
consignment.
Materials shall only be brought to site from a
previously tested and approved source, and any
materials not conforming to the requirements of the
Specification shall be rejected by the Engineer and
removed from the work site.
Coarse and fine aggregates supplied to the

site shall be paid for in cubic metres. The actual
volume of the aggregates to be paid for shall be
computed after deducting the specified percentages
in Table 500-28, from the volume computed by stack
measurements, to allow for bulking.
Page 462 of 1427

Unless otherwise directed by the Engineer,
measurements shall not be taken until sufficient
materials for use on the road have been collected and
stacked. Immediately after measurement, the stacks
shall be marked by white wash or other means as
Stone filler as delivered to the site shall be
measured in tonnes.
TABLE 500-28. PER CENT REDUCTION IN

VOLUME OF AGGREGATES
S.No. Standard size of aggregates Percentage re

compu
measuremen
volume
1. 75 mm and 63 mm
2. 45 mm and 26.5 mm
3. 22.4 mm, 13.2 mm, 11.2 mm and 6.7 mm
4. Fine aggregate
514.6. Rates
The contract unit rates for different sizes of

coarse aggregate, fine aggregate and stone filler shall
be payment in full for collecting, conveying and
stacking or storing at the site including full
Page 463 of 1427

compensation for :
(i) all royalties, fees, rents where
necessary;
Page 464 of 1427

(ii) all leads and lifts; and
incidentals to complete the work to
the Specifications.
(iv) all necessary testing of material, both
initial, to approve the source, and
regular control testing thereafter.
515. MASTIC ASPHALT
515.1. Scope
This work shall consist of constructing a

single layer of mastic asphalt wearing course for
road pavements and bridge decks.
Mastic asphalt is an intimate homogeneous
mixture of selected well-graded aggregates, filler
and bitumen in such proportions as to yield a plastic
and voidless mass, which when applied hot can be
trowelled and floated to form a very dense
impermeable surfacing.
515.2. Materials
515.2.1. Binder: Subject to the approval of

the Engineer, the binder shall be a paving grade
bitumen meeting the requirements given in Table
500-29.
515.2.2. Coarse aggregate : The coarse

aggregate shall consist of crushed stone, crushed
gravel/shingle or other stones. They shall be clean,
Page 465 of 1427

hard, durable, of fairly cubical shape, uncoated and
free from soft, organic or other deleterious
substances. They shall satisfy the physical

PHYSICAL PROPERTIES OF BINDER
Property Test meth

Penetration at 25°C IS 120
Softening point, °C IS 120
Loss on heating for 5h at 163°C, % by mass Max. IS 121
Solubility in trichloroethylenc, % by mass Min. IS 121
Ash (mineral matter), % by mass Max. IS 121
* In cold climatic regions (temperature 10°C), a
softer penetration grade of 30/40 may be used.
requirements given in Table 500-3.
The percentage and grading of the coarse
aggregate to be incorporated in the mastic asphalt
depending upon the thickness of the finished course
shall be as specified in Table 500-30.
Page 466 of 1427

TABLE 500-30. GRADE AND THICKNESS OF
MASTIC ASPHALT PAVING,
AND GRADING OF COARSE AGGREGATE
Application Thickness Nominal Coarse

range size aggregate
(mm) of coarse content, %
aggregate by mass
(mm) of total
mix
Roads and 25-50 13 40 ± 10

carriageways
Heavily 40-50 13 45 ± 10
stressed areas
i.e.
junctions and
toll plazas
Nominal size 13 mm
of coarse Cumulative % passing by weight
aggregate IS
Sieve (mm)
Page 467 of 1427

19 100
13.2 88-96
2.36 0-5
Fine aggregate: The fine aggregate shall be

the fraction passing the 2.36 mm and retained on the
0.075 mm sieve consisting of crusher run screening,
natural sand or a mixture of both. These shall be
clean, hard, durable, uncoated, dry and free from soft
or flaky pieces and organic or other deleterious
substances.
Filler : The filler shall be limestone powder

passing the 0.075 mm sieve and shall have a calcium
carbonate content of not less than 80 percent by
weight when determined in accordance with IS:
1514.
The grading of the fine aggregate inclusive of
filler shall be as given in Table 500-31.
TABLE 500-31. GRADING OF FINE

AGGREGATE (INCLUSIVE OF FILLER)
I.S. Sieve Percentage by weight
of aggregate
Passing 2.36 mm but 0-25
retained on 0.600 mm
Page 468 of 1427

Passing 0.075 30-55
515.3. Mix Design
515.3.1. Hardness number: The mastic

asphalt shall have a hardness number at the time of
manufacture of 60 to 80 at 25°C prior to the addition
of coarse aggregate and 10 to 20 at 25°C at the time
of laying after the addition of coarse aggregate.
Page 469 of 1427

The hardness number shall be determined in
accordance with the method specified in 15:1195-
1978.

shall be so fixed as to achieve the requirements of
the mixture specified in Clause 515.3.1. and shall be
in the range of 14 to 17 per cent by weight of total
mixture as indicated in Table 500-32.
TABLE 500-32. COMPOSITION OF MASTIC

ASPHALT BLOCKS WITHOUT
COARSE AGGREGATE
IS Sieve Percentage by weigh
Minimum
Passing 2.36 mm but retained on 0.600 mm 0
Passing 0.075 mm 25
Bitumen Content 14
5153.3. Job mix formula: The Contractor

shall inform the Engineer in writing at least 1 month
before the start of the work of the job mix formula
proposed to be used by him for the work, indicating
the source and location of all materials, proportions
of all materials such as binder and aggregates, single
definite percentage passing each sieve for die mixed
Page 470 of 1427

aggregate and results of the tests recommended in
the various Tables and Clauses of this Specification.

The provisions of Clause 501.5.1 shall apply, except
that laying shall not be carried out when the air
temperature at the surface on which the Mastic
Asphalt is to be laid is below 10°C.

on which mastic asphalt is to be laid shall be
prepared, shaped and conditioned to the profile
required, in accordance with Clause 501 or 902 as
appropriate or as directed by the Engineer. In the
case of a cement concrete base, the surface shall be
thoroughly power brushed clean and free of dust and
other deleterious matter. Under no circumstances
shall mastic asphalt be spread on a base containing a
binder which might soften under high application
temperatures. If such material exists, the same shall
be cut out and repaired before the mastic asphalt is
laid.
515.4.3. Tack coat: A tack coat in

accordance with Clause 503 shall be applied on the
base or as directed by the Engineer.
515.4.4. Preparation of mastic asphalt:

Penetration of mastic asphalt consists of two stages.
The first stage shall be mixing of filler and fine
Page 471 of 1427

aggregates and then heating the mixture to a
temperature of 170°C to 210°C. Required quantity of
bitumen shall be heated to 170°C to 180°C and
added to the heated aggregated. They shall be mixed
and cooked in an approved type of mechanically
agitated mastic cooker for some time till the
Page 472 of 1427

materials are thoroughly mixed. Initially the filler
alone is to be heated in the cooker for an hour and
then half the quantity of binder is added. After
heating and mixing for some time, the fine
aggregates and the balance of binder are to be added
and further cooked for about one hour. The second
stage is incorporation of coarse aggregates and
cooking the mixture for a total period of 3 hours.
During cooking and mixing, care shall be taken to
ensure that the contents in the cooker are at no time
heated to a temperature exceeding 210°C.
Where the material is not required for
immediate use it shall be cast into blocks consisting
of filler, fine aggregates and binder, but without the
addition of coarse aggregate, weighing about 25 Kgs
each. Before use, these blocks shall be reheated to a
temperature of not less than 175°C and not more
than 210°C, thoroughly incorporated with the
requisite quantity of coarse aggregates and mixed
continuously. Mixing shall be continued until laying
operations are completed so as to maintain the coarse
aggregates in suspension. At no stage during the
process of mixing shall the temperature exceed
210°C.
The mastic asphalt blocks (without coarse
aggregate) shall show on analysis a composition
within the limits as given in Table 500-32.
The mixture shall be transported to the laying
site in a towed mixer transporter having arrangement
for stirring and keeping the mixture hot during
transportation.
Page 473 of 1427

515.4.5. Spreading : The mastic asphalt
shall be laid, normally in one coat, at a temperature
between 175°C and 210°C and spread uniformly by
hand using wooden floats or by machine on the
prepared and regulated surface. The thickness of the
mastic asphalt and the percentage of added coarse
aggregate shall be in accordance with Table 500-30
or as specified by the Engineer. Where necessary,
battens of the requisite dimensions should be
employed. Any blow holes that appear in the surface
shall be punctured while the material is hot, and the
surface made good by further floating.
515.4.6. Joints : All construction joints shall

be properly and truly made. These joints shall be
made by warming existing mastic asphalt by the
application of an excess quantity of the hot mastic
asphalt mixture which afterwards shall be trimmed
to leave it flush with the surfaces on either side.
515.4.7. Surface finish : The mastic asphalt

surface can have poor skid resistance after floating;
in order to provide resistance to skidding, the mastic
asphalt after spreading, while still hot and in a plastic
condition, shall be covered with a layer of stone
aggregate. This aggregate shall be 13.2 mm size
(passing the 19.0 mm sieve and retained on the 9.5
mm sieve) or 9.5mm size (passing the 13.2 mm sieve
and retained on the 6.7 mm sieve) subject to the
approval of the Engineer. Hard stone chips,
complying with the quality requirements of Table
500-17, shall be precoated with bitumen at the rate
Page 474 of 1427

of 2±0.4% of S-65 penetration grade. The addition of
2% of filler complying with Table 500-9 may be
required to enable this quantity of binder to be held
without draining. The chips shall then be applied at
the rate of 0.005 cu. m. per 10 sq.m. and rolled or
otherwise pressed into the surface of the mastic layer
when the temperature of the mastic asphalt is not
less than 100°C.

the work when the mastic asphalt temperature at the
mid-depth of the completed layer has cooled to the
daytime maximum ambient temperature.
Page 475 of 1427

Control of Work

Clause 902.
The surface of the mastic asphalt, tested with
a straight edge 3.0m long, placed parallel to the
centre line of the carriageway, shall have no
depression greater than 7mm. The same limit shall
also apply to the transverse profile when tested with
a camber template.

Mastic asphalt shall be measured as finished

work in square metres at a specified thickness, or by
weight in tonnes as stated in the Contract.
515.9. Rate
The contract unit rate for mastic asphalt shall

be payment in full for carrying out the required
Page 476 of 1427

components listed under Clause 501.8.8.2. (i) to (ix).
516. SLURRY SEAL
516.1. Scope
Slurry seals are mixtures of fine aggregate,

portland cement filler, bitumen emulsion and
additional water. When freshly mixed, they have a
thick consistency and can be spread to a thickness of
1.5-5 mm. They may be used to seal cracks, arrest
fretting and fill voids and minor depressions, to
provide a more even riding surface or a base for
further treatment; they may also be used on top of a
single coat surface dressing.
516.2. Materials
The materials for slurry seal immediately

prior to mixing shall conform to the following
requirements:
516.2.1. Emulsified bitumen: The

emulsified bitumen shall be a cationic rapid setting
type as approved by the Engineer, conforming to the
requirements of IS: 8887. Where special mobile
mixing machines are available, Class A4* rapid
*
The corresponding grades in IS:8887 are only
broadly classified as RS, MS and SS and further sub-
classification is not available at present.
Page 477 of 1427

setting or Class K.3* road emulsions to BS 434: Part
1 should be used to obtain very early resistance to
Page 478 of 1427

traffic and rain. Generally, emulsion for slurry seal
should be capable of producing a slurry that will
develop early resistance to traffic and rain and is
sufficiently stable to permit mixing with the
specified aggregate, without breaking during the
mixing and laying processes. If approved by the
Engineer, a slow setting emulsion may be used.
Guidance on selection of an appropriate grade of
emulsion is given in the Manual for Construction
and Supervision of Bituminous Works.
516.2.2. Water : Water shall be of such

quality that the bitumen will not separate from the
emulsion before the slurry seal is in place.
The pH of the water must lie in the range 4 to
7, and if the total dissolved solids in the water
amount to more than 500ppm, the Engineer may
reject it, or order the Contractor to conduct a trial
emulsion mix to demonstrate that it does not cause
early separation.
516.2.3. Aggregate : The aggregate shall be

crushed rock, or slag and may be blended, if
required, with clean, sharp, naturally occurring sand
free from soft pieces and organic and other
deleterious substances to produce a grading as given
in Table 500-33. The aggregates shall meet the
requirements of the film stripping test (IS: 6241),
and a suitable amount and type of anti-stripping
agent added, as may be needed (details given in
Appendix 5).
Page 479 of 1427

516.2.4. Additives: It is usual to use ordinary
Portland cement, hydrated lime or other additives to
control consistency, mix segregation and setting rate.
The proportion of the additive should not normally
exceed 2 per cent by weight of dry aggregates.
A range of residual binder contents for each

aggregate given in Table 500-33. The optimum
mixture design for the aggregate, additive, water and
bitumen emulsion mixture should be determined in
accordance with ASTM D 3910.

Page 480 of 1427

TABLE 500-33. AGGREGATE GRADING,
BINDER CONTENT AND
APPROXIMATE COVERAGE RATE
Sieve Size (mm) Percentage by mass passing finished t
5 mm 3mm
9.5 100 --
4.75 90-100 100
3.35 -- 80-100
2.36 65-90 75-100
1.18 45-70 55-90
0.600 30-50 35-70
0.300 18-30 20-45
0.150 10-21 10-25
0.075 5-15 5-15
Quantity of residual binder, 7.5-13.5 10- 16
percentage by mass of
aggregate
Approximate coverage 8-15 4-6
rate(kg/m2)
516.4.2. Surface preparation: Any

necessary remedial work to the road surface and
structure shall be completed either prior to or as part
of the Contract and agreed as acceptable by the
Engineer, according to the provisions of Clause 501.
Before slurry seal is applied, street furniture
and, where directed by the Engineer, road markings,
shall be masked using self-adhesive masking
material or other material firmly secured against the
passage of the spreader box or the tools used for
Page 481 of 1427

hand laying. Any packed mud or other deposits on
the surface shall be removed, all organic growth
shall be removed by suitable means, and the surface
shall be swept free of all loose material.
516.4.3. Tack coat: If required by the

Engineer, a tack coat may be applied prior to the
slurry seal, with or without grit or chips, in order to
seal the existing substrata and enhance the bond to
the existing road surface. Unless otherwise agreed by
the Engineer, the rate of spread of tack coat shall be
0.15 to 0.30 litres/m2 for bituminous surfaces and 0.4
to 0.6 litres/m2 for concrete surfaces
516.4.4. Mixing and transportation of

mixture: Mixing (and laying) techniques vary
according to the type of emulsion used. For class A4
rapid setting and K3 emulsions, only special mobile
mixing machines should be used. These carry
supplies of aggregate, emulsion, water arid filler
(e.g. ordinary Portland cement or hydrated lime) and
are fitted with metering devices to feed the
ingredients in their correct proportions to a mixer
fitted to the rear of the machine. From the mixer the
slurry is fed into the screed box towed by the
machine.
For all other emulsions, mixing may be by
hand, concrete mixer or other mixer which
effectively coats the aggregate uniformly and
produces a slurry seal of suitable consistency for
satisfactory laying. For large areas, a bulk transit
concrete mixer may be used into which the
Page 482 of 1427

ingredients (including water) are measured and
mixed as the mixer travels to the area to be treated.
A screed box fitted with an adjustable rubber screed
should be towed by the mixer which feeds it during
laying.
Page 483 of 1427

The special mobile mixing machine, when
used, shall be capable of uniform application to
provide a continuous surface without ridges or
segregation. Before laying begins, the Contractor
shall provide the Engineer with a test certificate
showing test results for rate of application carried
out under the supervision of a competent authority,
demonstrating that the machine has been tested,
using the system to be used in the Contract, not more
than six weeks before the commencement of the
work.
Where the material is to be hand laid, the
slurry may be supplied to site pre-mixed in suitable
containers and steps shall be taken to ensure that the
material in each container is of an even consistency
throughout the container immediately prior to use.
516.4.5. Application: Transverse joints for

machine laid areas shall be formed with spreading,
starting and finishing on a protective strip not less
than 100 mm wide at each end of the lane length
being treated Transverse joints shall be formed such
that there shall be no ridges or bare strips.
Unless otherwise approved by the Engineer,
longitudinal joints shall coincide with lane markings.
Longitudinal joints shall be formed such that there
shall be no ridges or bare strips.
Hand work around street furniture and other
obstructions should meet the same performance
requirements and form a homogeneous surface with
the rest of the treated carriageway.
Footways and other confined areas may be
Page 484 of 1427

spread by hand using squeegees and brooms.
Transverse joints shall be formed with spreading,
starting and finishing on a protective strip not less
than 100 mm wide at each end of the lane length
being treated. Transverse joints shall be formed such
that there shall be no ridges or bare strips. Kerb
edges and other areas not being treated shall be
suitably masked with self adhesive masking
material. Footways shall be finished by dragging a
dampened broom transversely over the footway
under its own weight.
All voids, cracks and surface irregularities
shall be completely filled. In warm dry weather the
surface, immediately ahead of the spreading, shall be
slightly damped by mist water spray applied
mechanically, or for hand laying by a hand operated
pressure sprayer, unless otherwise approved by the
Engineer.
516.4.6. Rolling: The need for rolling shall

be as instructed by the Engineer. Where rolling is
required, a pneumatic-tyred roller having an
individual wheel load between 0.75 and 1.5 tonnes
shall be used, or as may be directed by the Engineer.
Rolling shall commence as soon as the slurry has set
sufficiently to ensure that rutting or excessive
movement will not occur.
Masking shall be removed after the slurry

seal has been applied, without damage to the edge of
Page 485 of 1427

the surfacing, and before opening the road or
footway to traffic.
The Contractor shall remove surplus
aggregate from the treated areas using a method
agreed by the Engineer. The Contractor shall
monitor the slurry seal closely for a minimum period
of 2 hours and if necessary the lane shall be swept
again. The monitoring shall continue until the slurry
seal has reached sufficient stability to carry
unrestricted traffic. If there are signs of distress, the
Engineer shall require the Contractor to reinstate
traffic safety and management procedures or other
such remedial action where necessary in order to
prevent further damage.
Page 486 of 1427

Further operations to remove subsequently
loosened aggregate shall be carried out over the next
48 hours. The areas treated and adjacent side roads,
footways and paved areas shall be kept substantially
free of loose aggregate for a period of 30 days after
completion of the work.

of Work
Generally, the surface finish of the completed

In addition, the finished slurry shall have a
uniform surface texture throughout the work,
without variations of texture within the lane width,
or from lane to lane, due to segregation of
aggregates, or due to variations in the
emulsion/water content of the mixture.
The finished surface shall be free from blow
holes and surface irregularities in excess of 3 mm
beneath a 1 metre straight edge due to scraping,
scabbing, dragging, droppings, excess overlapping or
badly aligned longitudinal or transverse joints,
damage by rain or frost, or other defects which
remain 24 hours after laying.
Page 487 of 1427

Slurry seal shall be measured as finished

work as specified, in square metres.
516.9. Rate
The contract unit rate for slurry seal shall be

components listed in Clause 501.8.8.2. (i) to (xi).
517. RECYCLING OF BITUMINOUS

PAVEMENT
517.1. Scope
This Clause of the Specifications covers the

recycling of existing bituminous pavement materials
to upgrade an existing bituminous pavement which
has served its first-intended purpose. The work shall
be performed on such widths and lengths as may be
directed by the Engineer and may consist of
pavement removal, stockpiling of materials from the
old pavement, addition of new bitumen and
untreated aggregate in the requisite proportions,
mixing, spreading and compaction of the blended
materials.
Recycling processes can be categorised into
Page 488 of 1427

in-situ recycling (where processing takes place on
site), and central plant recycling (where reclaimed
material is processed off site). The processes can be
further sub-divided into hot and cold processes. This
Specification covers the hot process only. However,
reclaimed aggregate from cold insitu recycling can
be used in the Bituminous Cold Mix process
specified in Clause 519, subject to the resultant
mixes achieving the specified standards.
Page 489 of 1427

517.2. Reclaimed Bituminous Materials for
Central Plant Recycling
517.2.1. Proportion of reclaimed materials

less than 10 per cent: If not more than 10% of
reclaimed bituminous material is to be used in the.
production of bituminous macadam or dense graded
bituminous base or binder course material, then
Clauses 517.2.2 to 517.2.9 do not apply. However:
a) all reclaimed bituminous material
shall be pre-treatcd before use such
that the material is homogeneously
mixed and the maximum panicle size
of reclaimed material docs not exceed
40 mm.
b) the mixed material shall comply with
the requirements of Clauses 504 or
507 as appropriate.
517.2.2. Proportions of reclaimed

materials greater than 10 per cent: Reclaimed
bituminous material of an amount greater than 10 per
cent, may be used in the production of bituminous
macadam and dense graded bituminous base and
binder course material, subject to the requirements of
Clauses 517.2.3 to 517.2.9 and subject to the
satisfactory completion of full trial investigations in
respect of all related materials, layer thickness,
machine operations and finished works on a case-by-
case basis entirely at the contractors cost and subject
to the approval of the Engineer. For estimating
purposes, a maximum amount not greater than 30
Page 490 of 1427

per cent reclaimed bituminous material should be
assumed.
517.2.3. Materials for recycled pavement:

The recycled materials shall be a blend of reclaimed
and new materials proportioned to achieve a paving
mixture with the specified engineering properties.
The reclaimed materials shall be tested and
evaluated to find the optimum blend meeting the
mixture requirements. Such testing and evaluation
shall be carried out on representative samples, either
cores sampled from the carriageway or samples
taken from stockpiles in accordance with current
practice. The sampling frequency should be
sufficient to determine how consistent the reclaimed
material is and to provide representative samples for
composition analysis and measurement of properties
of recovered binder. As an absolute minimum, one
sample to represent 500m of lane carriageway shall
be taken.
517.2.4. Bitumen extraction : The

procedure described in ASTM D-2172 shall be used
to quantitatively separate aggregate and bitumen
from any representative sample of reclaimed
bituminous pavement.
517.2.5. Aggregate evaluation: Mechanical

sieve analysis (IS: 2386, Part I, wet sieving method)
shall be performed on the aggregate portion of the
reclaimed bituminous pavement sample to determine
the grading. It is essential that the reclaimed
Page 491 of 1427

materials to be recycled are consistent, as variable
materials will cause problems with the control of
quality and impede the efficiency of the recycling
operation. Suitable sources of consistent material of
sufficient quantity for the scheme being considered
need to be identified either in existing pavements,
from stockpiled planings of known origin or from
another suitable source, before a decision can be
made on the optimum percentage of reclaimed
material.
After selecting the proportion of reclaimed
materials to be recycled, the grading of the mixture
may need adjustment, to meet Specification
requirements, by the addition of selected aggregate
sizes.
517.2.6. Evaluation of bitumen : When the
amount of reclaimed bituminous materials to be used
in the mixture exceeds 10%, the penetration value of
the recovered binder from the reclaimed bituminous
material, before mixing, shall exceed 15 pen, after
recovery of binder in accordance with the
requirements of BS 2000 : Part 397, when tested in
accordance with IS : 1203. Provided the above
requirement is met hardening of the old binder,
during the original mixing processor through ageing,
can be compensated for by adding a softer bitumen,
to obtain the appropriate final grade of binder.
The determination of the type and amount of
binder required to be added in the final mix is
essentially a trial and error procedure.
After mixing with recycled materials, the
binder recovered from the mixture shall have a
Page 492 of 1427

recovered penetration value not less than the value
TABLE 500-34. MINIMUM RECOVERFD

BINDER PENETRATION OF
RECYCLED MIXTURE
Specified Grade of Binder Minimum Recovered Penetration Value
(Penetration) of Binder after Mixing
45 27
65 39
90 54
517.2.7. Rejuvenators: The use of

rejuvenators, and a test to measure their
effectiveness, is described in Clause 517.6.3.
517.2.8. Untreated aggregate : if necessary,

fresh untreated aggregate shall be added to the
reclaimed bituminous pavement to produce a mix
with the desired grading The aggregate shall be
checked for quality requirements in accordance with
Table 500-3 or Table 500-8 as appropriate.
Reclaimed aggregate, if any, or any aggregate
normally used for the desired bituminous mixture, or
both, may be used for this purpose.
517.2.9. Combined aggregate grading : The

blend of reclaimed and new aggregate shall meet the
grading criteria specified in the relevant parts of
Clause 504 or 507, as appropriate and as approved
by the Engineer. The blend of aggregates shall be
checked for resistance to stripping as specified in
Page 493 of 1427

Tables 500-3 or 500-8 as appropriate.
The combined aggregate grading and binder

content shall comply with the relevant tables in
Clauses 504 or 507. For dense graded bituminous
mixtures the mixture design shall also comply with
the requirements of Table 500-11.
517.4. Reclaiming Old Pavement

Materials
The removal of pavement materials to the

required depth shall be accomplished either at
ambient temperature (cold process) or at an elevated
temperature (hot process), as approved by the
Engineer.
517.4.1. Cold removal process: In the cold

process, the ripping and crushing operations shall be
carried out using scarifiers, grid rollers, or rippers or
by any other means as directed by the Engineer. The
removed materials shall be loaded and hauled for
crushing to the required size as directed by the
Engineer. Alternatively, cold milling or planing
machines can be used to reclaim bituminous
pavement to controlled depths. After
Page 494 of 1427

the bituminous layers are removed, any remaining
aggregate materials that are to be incorporated in the
recycled hot mixture shall be scarified and removed.
When the pavement material removal is completed,
any drainage deficiencies shall be corrected. After
that, the base/sub-base as the case may be shall be
cut, graded and compacted to the required profile
and density.
517.4.2. Hot removal process: In this

process, the road surface shall be heated, by any
suitable means approved by the Engineer, before
scarification. A self propelled plant shall be used,
and a milling drum that follows the planer removes
the heated soft bituminous layer. The depth, width
and speed of travel shall be adjusted to suit specific
requirements as directed by the Engineer. During the
heating process, the surface temperature of the road
shall not exceed 200°C for more than 5 minutes.
517.4.3. Stockpiling: In the cold process, the

reclaimed bituminous pavement material shall be
stockpiled with the height of stockpiles not
exceeding 3 m. The reclaimed untreated aggregate
base/sub-base material shall be stockpiled in the
same manner as new aggregate. The number and
location of stockpiles shall be carefully planned for
efficient operation of the hot-mix plant.
517.5. Mixing and Laying
Generally, the requirements of Clauses 504.3
Page 495 of 1427

or 507.4, as appropriate, shall apply.
517.6. In Situ Recycling - The Remix and

Repave Processes
These processes are suitable for the

production of bituminous concrete wearing course in
accordance with the provisions of Clause 509.
517.6.1. Scope: In the process of repaying,

the existing surface is preheated and scarified but the
scarified material is not removed. A laver of fresh
bituminous mix material prepared in the integrated
mixing unit of the plant is then spread evenly on the
scarified surface to give a uniform profile. The
spread material should be compacted as soon as
possible after laying. In the process the total
thickness of the pavement is increased by up to
50mm.
In the remix process, the scarified material
should be taken from the mixing unit of the plant
where it is recycled with fresh binder, aggregate and
recycling agent. Then the recycled mixture is spread
on the preheated surface and tamped and compacted
to the required profile.
517.6.2. Heating and scarifying: Surfaces to

be treated shall be heated by plant with surfaces
insulated and fully enclosed. The heated width of
surfacing shall exceed the scarified width by at least
75 mm on each side, except against the edge of the
carriageway or kerb face. When new surfacing
Page 496 of 1427

material is spilled onto the road surface it shall be
removed before the existing surface is heated and
scarified. Areas of unscarified material shall not
exceed 50 mm x 50 mm.
The depth of scarification shall be such that
the bottom of the scarified layer is parallel to and
below the finished road surface level by the
thickness of wearing course material specified. A
tolerance of ± 6 mm is permissible.
Where street furniture and other obstructions
occur, these shall be suitably protected or removed
and the void covered. Surface dressing and large
areas of road
Page 497 of 1427

markings shall be removed by milling, planing,
scarifying or by similar approved processes.
The heated surface shall be evenly scarified
to comply with the requirements of this Clause.
When street furniture is left in place or raised, the
adjacent areas shall be scarified by other means, with
the material either left in place or removed, prior to
passage of the machine. If furniture needs to be
repositioned on completion of work, the new
wearing course material shall be used to make good
the road surface for a maximum width of 200 mm
around the obstruction.
Daring the reheating process the surface
temperature of the road shall not exceed 200°C for
more than 5 minutes.
517.6.3. Rejuvenator: For Remix, when

required, rejuvenator shall be uniformly sprayed
across the full-width of the processed material. The
machine shall incorporate a meter for continuous
verification of quantities which shall be within ±5%
of the specified rate. The volume of rejuvenator shall
vary in relation to the operating speed of the
machine, which shall be related to the volume of
material mixed or scarified.
The rejuvenator shall be a non-emulsified
aromatic extract. Us properties shall be verified
using the Rolling Thin Film Oven Test.
Rejuvenation of the existing pavement may
also be performed by adding new hot-mix
bituminous material containing a soft binder of
suitable penetration for restoring the binder in the
Page 498 of 1427

existing pavement to the required penetration.
517.6.4. Mixing: When required, new hot-

mix material shall be mixed with the heated and
scarified road pavement material in a pugmill within
the Remix machine, observing the mixing
temperatures specified in Table 500-5.
After mixing, the recycled bituminous
materials shall be automatically fed to a finishing
unit, which spreads and levels the mixture to the
specified thickness and cross-section. The new
bituminous concrete wearing course shall be material
complying with Clause 509.
517.6.5. Additional material (general): The

proportion of new hot-mix bituminous material, and
the proportion of existing bituminous pavement
material shall be as directed by the Engineer,
together with the amount me road surface level is to
be raised (if any).
The type and quantity of the new hot-mix
material shall be determined by using the Marshall
Mix Design procedure specified in The Asphalt
Institute Manual MS-2, before work commences.
Remix designs shall incorporate the stated
proportion of material sampled from the existing
road surface.
When additional coarse or fine aggregate or
filler are required to be added, they shall comply
with the requirements of Clause 509.2. The amount
of additional coarse or fine aggregate or filler to be
added to the existing bituminous pavement material
Page 499 of 1427

shall be notified to the Engineer.
517.6.6. Additional aggregate (remix

process): The coarse aggregate, fine aggregate and
filler added to the Remixed material shall comply
with the requirements of Clause 509.2.
517.6.7. New surfacing (repave and

remix/repave processes): New surfacing material
shall be bituminous concrete wearing course
complying with Clause 509, or other wearing course
material approved by the Engineer.
Page 500 of 1427

The new surfacing material shall be laid on,
and compacted with, the reprofiled surfacing, which
shall be at a temperature within the range of 100°C
to l50°C.
517.6.8. Binder: The binder shall be

recovered from samples taken from each layer of
material laid. The method of recovery shall be in
accordance with BS 2000 : Part 397 or an equivalent
test. The penetration of the binder shall be in the
range 35-70 pen.
517.6.9. Mixture design: The surfacing

material shall be sampled from the paver hopper or
augers. Care shall be taken that only the material
forming the new surface layer is sampled. The
sample shall be reduced on site by rifling or
quartering to approximately 5 kg and placed loose in
an air-tight container.
The sample shall only be reheated once
whilst within the container. As soon as the sample
reaches the required temperature, the reheated
material shall be remixed and three Marshall test
specimens prepared in accordance with the
procedures specified in MS-2.
The bulk density of each specimen shall be
measured before Marshall Stability testing. The
mean stability and flow of the three specimens,
measured in accordance with the procedures
specified in MS-2, shall comply with the
requirements of Table 500-19.
Finally the 3 Marshall specimens shall be
Page 501 of 1427

combined and the maximum theoretical specific
gravity (Gmm) of the mixture is determined in
accordance with ASTM D 2041. This maximum
theoretical specific gravity (Gmm) corresponds to 0%
air voids in the mixture. The actual bulk specific
gravity of a Marshall specimen determined in the
Laboratory. (Gmb ) will naturally be less than Gmm.
The percent air voids (P) in the specimen of the
compacted mixture given by Pa = Gmm – Gmb x 100
should
Gmm
meet the requirements of air voids laid down in
Table 500-19.
For recycled material forming the base or

binder course layer, Clause 1.5 or 507.5 shall apply
as appropriate. For recycled material forming :
wearing course layer, Clause 509.5 shall apply.

Clause 902.
supplied and the works carried out the relevant
Page 502 of 1427

The recycled pavement work shall be

measured in cubic metres or of finished work as
stated in the Contract.
Page 503 of 1427

517.11. Rate
The contract unit rate for recycled pavement

operations including full compensation for all items
as Clause 501.8.8.2. (i) to (xi)
518. FOG SPRAY
518.1. Scope
Fog spray is a very light application of low

viscosity bitumen emulsion 1 for purposes of sealing
cracks less than 3mm wide or incipient fretting or
disintegration in an existing bituminous surfacing,
and to help reduce loosening of chips by traffic on
newly finished surface dressing.
518.2. Material
The bitumen emulsion shall be as specified in

the Contract or as instructed by the Engineer. The
emulsion shall be
SS-1h* (SS-1 can be used if the former is not
available) complying with the requirements of
ASTM D-977. or;
CSS-1h* (CSS-1 can be used if the former is
not available) complying with the requirements of
ASTM D-2397.
Before use these emulsions shall be diluted, 1
pan emulsion to 1 part water. Alternatively, Class
Page 504 of 1427

A1-40* or K1-40* emulsions complying with the
requirements of BS434 : Part 1:1984 may be used.
These emulsions have a lower viscosity than the
above ASTM grades, they are rapid setting and they
do not require to be diluted. Because of their low
viscosity they should be used as soon as possible
after delivery. If this is not possible, the drums
should be very thoroughly rolled before use.
Spraying shall not take place when the

temperature is below 10°C, nor in windy or dusty
conditions, nor when it is raining or the surface to be
sprayed is wet (a damp surface is acceptable but
refer to Clause 518.4.2.).
518.4.1. Equipment: The fog spray shall be

applied by means of a self-propelled or towed
bitumen pressure sprayer complying with the
requirements of the Manual for Construction and
Supervision of Bituminous Works. The spray bar
should be protected from gusts of wind by means of
a hood.
518.4.2. Preparation of surface: The
*
The grades in IS:8887 are only broadly classified as
RS, MS and SS and further sub-classification is not
available at present.
Page 505 of 1427

surface on which the fog spray is to be applied shall
be thoroughly cleaned with compressed air,
scrubbers etc. The cracks shall be cleaned with a
pressure air jet to remove all dirt, dust etc.
Page 506 of 1427

518.4.3. Application: The fog seal shall be
applied at a rate of 0.5-1.0 litres/m2, using equipment
such as pressure tank, flexible hose and spray bar or
lance.
518.5. Blinding
If specified in the Contract or ordered by the

Engineer, the fog spray shall be blinded with graded
grit of 3mm size and under, coated with about 2 per
cent of the emulsion by weight. The pre coated grit
shall be allowed to he cured for at least one week or
until they become non-sticky and can be spread
easily.
518.6. Quality Control of Work

During the spraying operations, arrangements

for traffic shall be made in accordance with the
provisions of Clause 112. The surface should not be
opened to traffic for 24 hours after spraying. If pick-
up does occur a light blinding of crusher dust or sand
should be applied.
Page 507 of 1427

Fog spray and blinding (if used) shall be
measured in terms of surface area of application, for
the area covered, in square metres.
518.9. Rate
The contract unit rate for fog spray and

blinding (if used) shall be payment in full for
compensation for all components listed in Clause
501.8.8.2. (i) to (xi) as applicable to the work
specified in these Specifications.
519. BITUMINOUS COLD MIX (INCLUDING

GRAVEL EMULSION)1
519.1. The Design Mix
Bituminous Cold Mix consists of a mixture

of unheated mineral aggregate and emulsified or
cutback bitumen. This Specification deals only with
plant mix (as opposed to mixed-in-place). Two types
of mix are considered, namely Designed Cold Mix
and Recipe Cold Mix. The Design Mix procedure
shall be used unless the Recipe Mix procedure is
1
This Specification Clause has been introduced for
the first time. Difficulties in using this Clause and
suggestions for improvement may be forwarded to
DG(RD). Ministry of Road Transport & Highways,
Transport Bhavan. Parliament Street, New Delhi-110
001. Fax # 3710236
Page 508 of 1427

specifically approved by the Engineer.
Page 509 of 1427

519.2. Designed Cold Mix
This Specification is based on The Asphalt

Institute Manual MS-14 which contains additional
information for guidance. These mixes tan
considered suitable for use as base course,
appropriate to their stability, in new work or major
repair work.
519.2.1. Materials
519.2.1.1. Binder: The binder shall be a

bituminous emulsion as specified in AASHTO M
140 (ASTM D977)* or AASHTO M 208 (ASTM
D2397)*, namely MS-2, MS-2h, HFMS-2, HFMS-
2h, HFMS-2s, SS-1, SS-1h, CMS-2, CMS-2h, CSS-1
and CSS-1h. Alternatively, a cutback bitumen as
specified in AASHTO M 82 (ASTM D2027) or
ASTM D 2026, namely MC 70, 250, 800 & 3000
and SC 250, 800 and 3000 may be used, or, if
approved by the Engineer, an equivalent material
which conforms with IS:8887 and IS:217.
A general guide for the use of these binders
is given in Table 500-35 and in the Manual for
Construction and Supervision of Bituminous Works.
However the final selection shall be made only after
laboratory evaluation with the aggregates to be used.
The binder with the highest residual viscosity at
*
The corresponding grades in IS:8887 are only
broadly classified as RS, MS and SS and further sub-
classification is not available at present.
Page 510 of 1427

ambient temperatures that can reasonably be
handled, by the mixing and laying equipment
proposed shall be used.
TABLE 500-35. USES OF BITUMEN IN

COLD MIX
Type Emulsified Bitumen Cu

of Construction
Anionic Cationic Mediu
Curing (
MS-2h, HFMS-2h
Cold-Laid Plant Mix MS-2, HFMS-2
Pavement Base and Surfaces
HFMS-2s
CMS-2h
CSS-1h
CMS-2
CSS-1
SS-1h
SS-1
250
800
70
Open-Graded Aggregate * * * *
Well-Graded Aggregate * * * * * * *
Patching, Immediate Use * * * * * *
Patching, Stockpile * *
519.2.1.2. Aggregates: The aggregates shall

comply with the requirements of Clause 504.2.2. and
504.2.3. If the aggregates are not properly coated
with anionic emulsion or cutback bitumen, a small
amount of hydrated lime, an approved antistripping
agent (see Appendix 5) or a change to cationic
emulsion shall be proposed by the Contractor, for the
Page 511 of 1427

Page 512 of 1427
519.2.1.3. Aggregate grading and binder
content: The combined aggregate grading for the
particular mixture, when tested in accordance with
IS:2386 Part 1, (wet sieving method), shall fall
within the limits shown in Table 500-36.
519.2.2. Mixture Design
519.2.2.1. Requirements for the mixture:

519.2.2.2. Binder content: The binder

content shall be optimised to achieve the
requirements of the mixture set out in Table 500-41.
The method adopted shall be that described in
Appendix F and H of Asphalt Institute’s Manual,
MS-14.
519.2.2.3. Job Mix Formula: The

Contractor shall inform the Engineer in writing, at
least one month before the start of the work, the job
mix formula proposed for use in the works and shall
give the following details:
(i) Source and location of all materials;
as follows where, each is applicable:
(a) Binder, as percentage by
weight of total mixture;
(b) Coarse aggregate/fine
aggregate as percentage by
Page 513 of 1427

weight of total
aggregate;
each sieve for the mixed aggregate;
(iv) The results of tests enumerated in
Contractor,
(v) Test results of the physical
characteristics of the aggregates to be used:
(vi) Spraying temperature of binder if
appropriate.
While working out the job mix formula, the

and its different
TABLE 500-36. AGGREGATE GRADING AND

BITUMEN CONTENT
Nominal maximum 9.5 13.2 19.0

size (mm)
Allowable thickness 25-35 36-50 51-75
(mm)
IS Sieve (mm) Cumulative % by weight of total aggr
26.5 - - 100
19.0 - 100 90-100
13.2 100 90-100 -
9.5 90-100 - 60-80
Page 514 of 1427

4.75 60-80 45-70 35-65
2.36 35-65 25-55 20-50
0.30 6-25 5-20 3-20
0.075 2-19 2-9 2-8
1
Guide to binder content. % by weight o
Cutback Min 4 to Max 6
Emulsion Min 7 to Max 10
1
To be determined by the modified Marshall Test.
TABLE 500-37. MIXTURE REQUIREMENTS

FOR DESIGNED COLD MIX
Parameter Emulsion1
Minimum Stability (kN at 22.2°C) 2.2 for paving 2.
Emulsion (kN at 250C) Cutback
Percent maximum stability loss on soaking 503
Minimum flow (mm) 2
Compaction level (number of blows) 50
Per cent voids in mineral aggregate (VMA) See Table
Per cent minimum coating6 50
Notes 1Using “Marshall method for emulsified

asphalt-aggregate cold mixture design”.
Appendix F. MS-14.
2
Using “Marshall method for cut-back
asphalt-aggregate cold mixture design”.
Appendix H. MS-14.
3
With vacuum saturation and immersion.
4
Four days soak at 25°C.
5
Refers to total voids in the mix occupied by
Page 515 of 1427

air and water.
6
CoatingTest. Appendix F MS-14.
TABLE 500-38. MINIMUM PER CENT VOIDS

IN MINERAL
AGGREGATE (VMA)
Nominal Maximum
Particle Size Minimum
IS Sieve (mm)
9.5
12.5
19.0
25.0
37.5
ingredients satisfy the physical and strength
requirements of these Specifications.
which samples selected jointly with the Engineer of
all ingredients of the mix shall be furnished by the
Contractor as required by the former.
effective unless and until modified by the Engineer.
Should a change in the source of materials be
proposed, a new job mix formula shall be established
and approved by the Engineer before actually using
the materials.
519.2.2.4. Permissible variation from the

job mix formula: It shall be the responsibility of the
Contractor to produce a uniform mix conforming to
the approved job mix formula, subject to the
Page 516 of 1427

permissible variations of the individual percentages
of the various ingredients in the actual mix from the
job mix formula to be used, within the
Page 517 of 1427

limits as specified in Table 500-39. These variations
are intended to apply to individual specimens taken
for quality control tests in accordance with Section
900.

limitations: Construction with cold mix must not be
undertaken when ambient temperatures below 10°C
are expected, during rain, in standing water, or
generally when poor weather is predicted. Bitumen
emulsions and cutbacks depend on the evaporation
of water and/or solvent for the development of their
curing and adhesion characteristics Cold weather,
rain and high humidity slow down the rate of curing.
Extra manipulation may be required to remove
volatiles in cool and humid conditions. Wind
increases the rate of evaporation.
TABLE 500-39. PERMISSIBLE VARIATIONS

FROM THE JOB
MIX FORMULA
Description Permissible v
Base/binder course
Aggregate passing 19mm sieve or larger ±8%
Aggregate passing 13.2mm. 9.5mm ±7%
Aggregate passing 2.36mm. 1.18mm. 0.6mm ±5%
Aggregate passing 0.3mm, 0. 1 5mm ±4%
Page 518 of 1427

519.2.3.2. Preparation of the base: The base
on which cold mix is to be laid shall be prepared,
shaped and levelled to the required profile in
accordance with Clauses 501 and 902 as appropriate,
and a prime coat, where specified, shall be applied in
accordance with Clause 502 or as directed by the
Engineer.
519.2.3.3. Tack coat: A tack coat in

accordance with Clause 503 shall be applied over the
base on which the cold mix is to be laid where
519.2.3.4. Preparation and transportation

of the mixture: Mixing can be carried out using one
of the following types of mixer, which is provided
with equipment for spraying the binder at a
controlled rate and, if necessary, for heating the
binder to a temperature at which it can be applied
uniformly to the aggregate:
(a) rotary drum type concrete mixer:
(b) single or twin shaft concrete or
macadam mixer;
(c) batch or continuous type mixer
without dryer or screens other than a
scalping screen.
A sufficient number of haul trucks with
smooth, clean beds should be available to ensure
continuous operation of the mixing plant. The type
of truck used for transporting the mixture from the
mixer to the road site must be suited to the
Page 519 of 1427

Contractor’s nominated laying procedure
methodology.
519.2.3.5. Spreading: Designed cold mix

shall be placed only when the specified density can
be obtained. The mixture shall not be placed on any
wet surface or when weather conditions will
otherwise prevent its proper handling or finishing.
Page 520 of 1427

If spreading by motor grader, the grader must
have a blade that is straight and sharp and long
enough to ensure finishing to close, straight,
transverse tolerances and all joints and linkages must
be in good condition. The grader must be heavy
enough to hold the blade firmly and uniformly on the
surface while spreading the mixture.
If climatic conditions and aggregate grading
permit evaporation of moisture or volatiles without
aeration by manipulation, a conventional self-
propelled asphalt paver shall be used to place
designed cold mix.
Other methods of spreading may be used as
519.2.3.6. Compaction: Initial compaction

of the laid material shall be carried out using a
pneumatic-tyred roller of a weight appropriate to the
layer thickness to be compacted with single layer
thicknesses being 25-100mm and all compaction
being in accordance with Clause 501.6 and Clause
501.7. Smooth tyres shall be used. Final rolling and
smoothing of the surface should be completed using
steel wheel rollers. The Contractor shall demonstrate
at laying trials that his proposed laying and
compaction methods can achieve a satisfactory
result.
519.2.4. Opening to traffic: Traffic shall not

be allowed to run on new work until all the water or
volatiles in the mixture have evaporated, as
determined by the Engineer. The rate of evaporation
Page 521 of 1427

will be influenced by the temperature, humidity and
wind conditions.

of work: The surface finish of construction shall
control of the quality of supplied materials and the
900 shall apply.

Clause 112.
519.2.7. Measurement for payment:

Designed Cold Mix shall be measured as finished
work, for the area covered, in cubic metres, by
weight in n.etric tonnes, or by square metres at a
specified thickness as specified in the Contract.

Designed Cold Mix shall be payment in full for
501.8 8 2 (i) to (xi) The rate shall cover the provision
of the specified grade of cutback in the mix at 5 per
cent of the weight of the total mix or emulsion at 8
per cent of the weight of the total mix, with the
provision that the variation of quantity of binde will
be assessed on the basis of the amount agreed by the
Engineer and the payment adjusted as per the rate for
Page 522 of 1427

cutback or emulsion quoted in the Bill of Quantities.
Recipe Cold Mix
519.3. Recipe Cold Mix
This Specification is based on BS434:Part

2:1984 which contains additional information. These
are premixes made with emulsion binder which are
laid immediately after mixing and while the
emulsion is still substantially in an unbroken state.
These
Page 523 of 1427

mixes are considered suitable for use only for
emergency and minor repair work and temporary
road surface improvement.
519.3.1. Materials
519.3.1.1. Binder: Emulsions of sufficient

stability for mixing with the particular graded
aggregate should be used. Grades of emulsion
quoted are in accordance with BS434: Fart 1:1984
but comparable grades to IS or AASHTO
specifications may be used. Guidance on selection of
an appropriate grade of emulsion is given in the
Bituminous Works. The corresponding grades in
IS:8887 are only broadly classified as RS, MS and
SS and further sub-classification is not available at
present.
519.3.1.2. Aggregates: Any normal, clean,

but not necessarily dry, aggregate can be used,
provided that it has a sufficiently high crushing
strength with regard to the traffic to be carried.
Typical gradings are given in Table 500-40.
519.3.1.3 Aggregate grading and binder

Part1 (wet sieving method) the combined aggregate
grading for the particular mixture shall fall within
the limits shown in Table 500-40. The grade and
range of quantity of emulsion arc also indicated in
this table. The actual quantity of emulsion to be used
Page 524 of 1427

shall be approved by the Engineer after seeing the
results of trial mixes made in the laboratory.
Page 525 of 1427

TABLE 500-40. COMPOSITION OF RECIPE
MIXES
Nominal Size 40 40 14 6
(mm) and type Single Open Open Medium
of Macadam course textured textured textured wearin
base wearing course
course course
Allowable
Thickness (mm) 75-100 75-100 31-50 21-30
IS Sieve Cumulative % by weight of total 2ggreg
Size mm
45 100 100 -- --
37.5 90-100 90-100 -- --
26.5 55-90 55-85 -- --
19 -- -- 100 --
13.2 35-55 15-35 90-100 --
9.5 -- -- 55-75 100
6.3 20-30 -- 25-45 90-100
3.35 10-20 0-10 15-25 45-65
2.36 -- -- -- --
1.18 -- -- -- 10-30
0.60 -- -- -- --
0.30 2-10 - -- --
0.15 -- -- -- --
0.075 -- -- 2-6 2-8
Emulsion grade and quantity
Generally A2-57(4) or A2 – 50(4)
Page 526 of 1427

Under some
circumstances -- -- -- A3
Quantity(1) 55 to 70 45 to 65 70 to 90 85 to 100
litres /tonne
Note: (1) For pricing purposes the lower
quantity in these ranges should he assumed
(2) With coarser grading quantity may
sometimes be reduced to 80
litres/tonne and with finer grading it
may sometimes be increased upto 135
litres/tonne.
(3) Use 0-70 litres/tonne of water as
necessary.
(4) A2-50 and A2-57 are British grades
of emulsion and their grading system
is explained in the Manual.

limitations: Construction with cold mix must not
undertaken when ambient temperatures below 10°C
are expected of generally when poor weather is
predicted. Bitumen emulsion and cutbacks depend
on the evaporation of water and/or solvent for the
development of their curing and adhesive
characteristics. Cold weather, rain, and high
humidity slow down the rate of curing. Extra
manipulation may be required to remove volitiles in
cool or humid conditions. Wind increases the rate of
evaporation.
Page 527 of 1427

519.3.2.2. Preparation of base: The base on
which the cold mix is to be laid shall be prepared
shaped and graded to the required profile in
accordance with Clauses 501 and 902 as appropriate,
and a prime coat if specified in the contract, or
required by the Engineer, shall be applied in
accordance with Clause 502, or as directed by the
Engineer.
519.3.2.3. Tack coat: A tack coat in

accordance with Clause 503 shall be applied over the
base on which the cold mix is to be laid if specified
in the Contract or required by the Engineer.
519.3.2.4. Preparation and transportation

of the mixture: Mixing shall be carried out using
one of the following types of mixer, which is
provided with equipment for spraying the binder at a
controlled rate, and, if necessary, for heating the
binder to a temperature at which it can be applied
uniformly to the aggregate:
(a) rotary dram type concrete mixer;
(b) single or twin shaft concrete or
macadam mixer,
(c) batch or continuous type mixer
without dryer or screens other than a
scalping screen.
A sufficient number of haul trucks with
smooth, clean beds should be available to ensure
continuous operation of the mixing plant. The type
of truck used for transporting the mixture from the
mixer to the road site must be suited to the chosen
Page 528 of 1427

laying procedure.
519.3.2.5. Spreading: The mixed material

should be spread immediately after preparation. The
mixture shall be placed only when the specified
density can be obtained. The mixture shall not be
placed on any wet surface or when weather
conditions will otherwise prevent its proper handling
or finishing.
If spreading by motor grader, the grader must
have a blade that is straight and sharp and long
enough to ensure finishing to close straight
transverse tolerances and all joints and linkages must
be in good condition. The grader must be heavy
enough to hold the blade firmly and uniformly’ on
the surface while spreading the mixture. On surface
courses, the tyres must be smooth.
The methodology for spreading shall be
approved by the Engineer prior to laying, and if
required a laying trial conducted to prove the laying
method satisfactory before approval.
519.3.2.6. Compaction: Initial compaction

of the laid material shall be carried out using a
pneumatic-tyred roller of a weight appropriate to the
layer thickness to be compacted with single layer
thicknesses being 25-l00mm and all compaction
being in accordance with Clause 501.6 and 501.7.
Smooth tyres shall be used. Final rolling and
smoothing of the surface should be completed using
steel wheel rollers. The Contractor shall demonstrate
at laying trials that his proposed laying and
Page 529 of 1427

compaction methods can achieve a satisfactory
result.
519.3.3. Opening to traffic: Traffic shall not

be allowed to run on new work until all the water or
volatiles in the mixture have evaporated. The rate of
evaporation will be influenced by the temperature,
humidity and wind conditions.

of work: The surface finish of construction shall
control of the quality of materials supplied and the
900
Page 530 of 1427

shall apply.

Clause 112.
519.3.6. Measurement for payment: Recipe

Cold Mix shall be measured as finished work, for the
area instructed to be covered, in cubic metres, by
weight in metric tonnes, or in square metres at a
specified thickness, as specified in the Contract.
519.3.7. Rate
The contract unit rate for Recipe Cold Mix

components listed in Clause 501.8.8.2. (i) to (xi).
The rate shall cover the provision of the specified
grade of emulsion at the lower quantity in the range
for each type of mix indicated in Table 500-44 with
the provision that the variation of quantity of
emulsion will be assessed on the basis of the amount
agreed by the Engineer and the payment adjusted as
per the rate for emulsion quoted in the Bill of
Quantities.
520. SAND ASPHALT BASE COURSE1
1
the first time Difficulties in using this Clause and
Page 531 of 1427

520.1. Scope
This work shall consist of a base course

composed of a mixture of sand, mineral filler where
required and bituminous binder, placed and
compacted upon a prepared and accepted subgrade
in accordance with these Specifications and the lines,
levels, grades dimensions and cross sections shown
on the Drawings or as directed by the Engineer.
Note: Sand Asphalt Base course is used in
special situations like quality coarse
aggregates not being available within
economical leads and/or water needed
for conventional base course not
being readily available, as in desert
areas.
520.2. Materials

paving bitumen of Penetration Grade S65 (60/70) or
S90 (80/100), as specified in the Contract, both as
per Indian Standard Specifications for “Paving
Bitumen” IS:73.
520.2.2. Sand: The sand shall be clean,

DG(RD). Ministry of Road Transport & Highways,
Transport Bhavan, Parliament Street, New Delhi -
110 001. Fax No. # 3710236.
Page 532 of 1427

naturally occurring or blended material free from
any deleterious substances, dry and well graded
within the limits given in Table 500-41 and with
other physical properties conforming to the
requirements of this table
520.2.3. Filler: When required, fillet shall

consist of finely divided mineral matter such as rock
dust, hydrated lime 01 cement as approved by the
Engineer. The filler shall
Page 533 of 1427

conform to Clause 507.2.4.
520.3. Mix Design

TABLE 500-41. SAND GRADING AND

PHYSICAL REQUIREMENTS
Sieve Size (mm) Cumulative perce

total aggre
9.5 1
4.75 85-
2.36 80-
1.18 70
0.60 55
0.30 30
0.15 10
0.075 4-
Plasticity Index (%) 6m
Sand equivalent (IS:2720, Part 37) 30
Los Angeles Abrasion Value (IS:2386, part 4) 40
Note : Maximum thickness for sand asphalt is 80
mm.
TABLE 500-42. REQUIREMENTS FOR SAND

ASPHALT BASE COURSE
Parameter Requirement
Page 534 of 1427

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

mixture set out in Table 500-46. The Marshall
shall be adopted as described in The Asphalt
Institute Manual MS-2.
520.3.3. Job mix formula : The Contractor

shall develop the job mix formula proposed for use
in the works and shall give the following details:
(i) Source and location of all materials;
as follows where each is applicable:
(a) Binder as percentage by
weight of total mixture;
(b) Sand/Mineral filler as
Page 535 of 1427

percentage by weight of total aggregate
including mineral filler;
Page 536 of 1427

each sieve for the mixed aggregate;
(iv) The results of tests enumerated in
Contractor;
(v) Test results of physical characteristics
of aggregates to be used;
(vi) Mixing temperature and compacting
temperature.
While working out the job mix formula, the

and its different ingredients satisfy the physical and
strength requirements of these Specifications.
which joint samples of all ingredients of the mix
shall be furnished by the Contractor as required by
the former.
effective unless and until modified by the Engineer.
Should a change in the source of materials be
proposed, a new job mix formula shall be established
and approved by the Engineer before actually using
the materials.
520.3.4. Permissible variation from job

mix formula : The Contractor shall produce a
uniform mix conforming to the approved job mix
Page 537 of 1427

formula, subject to the permissible variations of the
individual percentages of the various ingredients in
the actual mix from the job mix formula to be used,
within the limits as specified in Table 500-43. These
variations are intended to apply to individual
specimens taken for quality control tests as described
in Section 900.
520.4.1. Weather and seasonal limitations :

520.4.2. Preparation of base : The surface

on which Sand Asphalt Basecourse Material is to be
laid shall be prepared, shaped and graded to the
profile required for the particular layer in accordance
with Clauses 501 and 902 as appropriate or as
directed by the Engineer. The surface shall be
thoroughly swept clean free from dust and foreign
matter using a mechanical brush, and the dust blown
off by compressed air. In confined locations where
mechanical plant cannot access, other methods shall
be used as approved by the-Engineer. A prime coat,
where specified, shall be applied in accordance with
Clause 502 or as directed by the Engineer.
TABLE 500-43. PERMISSIBLE VARU.TIONS

FROM THE JOB MIX FORMULA
Description Permissible variation

Page 538 of 1427

Aggregate passing 2.36mm. ±5%
1.18mm. 0.6mm
Aggregate passing 0.3mm, ±4%
0.15mm
Aggregate passing ±2%
0.075mm
Mixing temperature ±100C
Page 539 of 1427

520.4.3. Tack coat : A tack coat over the
base shall be applied in accordance with Clause 503,
or otherwise as directed by the Engineer.
520.4.4. Preparation and transportation of

the mixture: The provisions of Clauses 501.3 and
501.4 shall apply.

Clauses 501.5.2 to 501.5.4. shall apply. Mixing must
be accomplished at the lowest temperature and in the
shortest time that will produce a mixture with
complete coating of the aggregate and at a suitable
temperature to ensure proper compaction. The ideal
mixing and compaction temperatures for the
particular bitumen in use shall be obtained from the
Bitumen Test Data Chart given in the Manual for
Construction and Supervision of Bituminous Works
and shall correspond to a viscosity of 2 Poise (0.2
Pa.s) and 3 Poise (0.3 Pa.s) respectively, based on
the original (unaged) bitumen properties. For
guidance, the ranges of acceptable mixing and
rolling temperatures for some typical penetration
grade bitumen are shown in Table 500-5.
520.4.6. Rolling: Clause 501.6 shall apply.

Generally the initial or breakdown rolling shall be
done with 8-10 tonne deadweight smooth-wheeled
rollers. The intermediate rolling shall be done with
8-10 tonne deadweight or vibratory rollers or with a
pneumatic tyred roller of 12-15 tonne weight having
a tyre pressure of at least 5.6 kg / sq.cm.. The finish
Page 540 of 1427

rolling shall be done with 8-10 tonne deadweight
smooth wheeled tandem rollers. The exact pattern of
rolling shall be established at the laying trials.

the final rolling when the temperature of the mixture
at the mid-depth of the completed layer has cooled to
the daytime maximum ambient temperature. When
daytime maximum ambient temperatures are in
excess of 35°C, great care is needed to ensure that
this criterion is met, particularly where slow moving
heavy traffic is involved.

of Work

Clause 902.

Page 541 of 1427

Sand Asphalt Basecourse materials shall be
measured as finished work, for the area covered, in
cubic metres, metric tonnes, or in square metres at a
specified thickness, as stated in the Contract.
Page 542 of 1427

520.9. Rate
The contract unit rate for Sand Asphalt

Basecourse materials shall be payment in full for
501.8.8.2 (i) to (xi). The rate shall cover the
provision of 5 per cent of bitumen by weight of the
total mixture.
The variation from the actual percentage of
bitumen approved by the Engineer and used will be
assessed and the rate adjusted, plus or minus, using
the rate for bitumen in the Bill of Quantities.
521. MODIFIED BINDER1
521.1. Scope
Modified binders comprise a base binder, to

which is added either natural rubber, crumb rubber
or a polymer such as Styrene-Butadiene-styrene
(SBS), Ethylene-Vinyl-Acetate (EVA) or Low
Density Polyethylene (LDPE). The purpose is to
achieve a high performance binder with improved
properties, particularly at extremes of temperature.
1
DG(RD), Ministry of Road Transport & Highways,
Transport Bhavan. Parliament Street, New Delhi -
110 001. Fax No. # 3710236.
Page 543 of 1427

521.2. Materials
521.2.1. Base Binder : The base binder into

which the modifier is incorporated shall conform to
IS:73. The choice of grade shall be such that it is
compatible with the modifier and, when mixed shall
have the properties described in Clause 521.3.
521.2.2. Modifier : The modifier shall be a

natural rubber, crumb rubber or any other polymer
which is compatible with the base binder and which
allows the properties given in Clause 521.3 to be
achieved. For further details. IRC:SP:53-1999 may
be referred to. The modifier, in the required quantity
shall be blended at the refinery or at the site plant
capable of producing modified binder.
521.3. Modifier Proportions
The quantity of modifier to be added shall be

determined by tests on the base binder and the
modified binder and the properties desired. A
reference may be made to the Manual for
Construction and Supervision of Bituminous Works
for indicative dosage of different types of modifiers.
The properties of the modified binder shall be as
given in Table 500-44, 500-45 or 500-46 according
to the requirements of the Contract.
521.4. Mixing
Page 544 of 1427

The modifier shall be blended with the base
binder so that it disperses thoroughly prior to use.
The type of mixing equipment used shall be suited to
the modifier type. Further guidance is given in the
Bituminous Works.
Page 545 of 1427

521.5. Quality Control of Materials
521.5.1. Binder Properties : For control of

the quality of the base binder, the relevant provisions
of Section 900 shall apply. Additionally, the
modified binder shall be tested for all the properties
listed in Table 500-44, 500-45 or 500-46 as
appropriate and certificates produced prior to use.
During use, the requirements for softening
point, penetration and elastic recovery shall be tested
regularly. If the modified binder is produced on site
then tests shall be carried out daily. If pre-blended
modified binder is used tests shall be carried out
weekly.
TABLE 500-44. REQUIREMENTS OF

POLYMER MODIFIED BINDERS
(ELASTOMERIC
THERMOPLASTICS AND
RUBBER LATEX)
Designation Grade and Requirements

PMB 120 PMB 70 PMB40
Penetration at 25°C, 0.1mm, 100g, 90 to 150 50 to 89 30 to 49
5 sec.
Penetration at 4°C, 0.1mm. 200g. 35 22 18
60-sec., Minimum*
Softening Point. (R&B). °C. 38 48 59
Minimum
Fraass Breaking Point, °C, -24 -16 -12
Maximum*
Ductility at 27°C, cm. Minimum 75 50 50
Page 546 of 1427

Flash Point, COC. °C, Minimum 220 220 220
Elastic Recovery of Half Thread 70 60 50
in Ductilometer at 15°C, %, (50)** (40)** (30)**
Minimum
Separation, Difference in 4 4 4
Softening
Point, R&B. °C, Maximum
Viscosity at 150°C, Poise 1-3 2-6 4-8
Test an Thin Film Oven Test Residue,
TFOT(IS:9382-1979)
PMB120 PMB 70 PMB40
Penetration at 4°C, 0.1 mm, 200g, 18 15 12
60 sec. Minimum*
Loss in Weight. %, Maximum 1.0 1.0 1.0
Increase in Softening Point. 0C, 7 6 5
Maximum
Reduction in Penetration at 25°C, 35 35 35
%, Maximum
in Ductilometer at 15°C, %, (35)** (30)** (25)**
Minimum
* Relevant to snow bound cold climate
areas
** Natural Rubber Modified Bitumen
Page 547 of 1427

521.5.2. Storage Stability: Pre-blended
modified binders which arc to be stored without
circulation or agitation facility shall be tested for
storage stability prior to use, in accordance with
Appendix1 of IRC:SP:53-1999. The mean of the
differences in softening point, top to bottom, of not
less than three pairs of samples shall not exceed 5°C.

(PLASTOMERIC
THERMOPLASTICS )

PMB 120 PMB 70 PMB40
Penetration at 25°C, 0.1mm, 100g, 90 to 150 50 to 89 30 to 49
5 sec.
Penetration at 4°C, 0.1mm. 200g. 35 22 18
60-sec., Minimum*
Minimum
Fraass Breaking Point, °C, -20 -15 -10
Maximum*
Ductility at 27°C, cm. Minimum 50 40 30
Flash Point, COC. °C, Minimum 220 220 220
ElasticRecovery of Half Thread in 60 50 40
Ductilometer at 15°C, %,
Minimum
Separation, Difference in 3 3 3
Softening Point, R&B. °C,
Maximum
Viscosity at 150°C, Poise 1-2 2-4 4-8
Page 548 of 1427

TFOT(IS:9382-1979)
PMB120 PMB 70 PMB40
Penetration at 4°C, 0.1 mm, 200g, 18 15 12
60 sec. Minimum*
Loss in Weight. %, Maximum 1.0 1.0 1.0
Maximum
%, Maximum
in Ductilometer at 15°C, %,
Minimum
* Relevant to snow bound cold climate areas
Other pre-blended modified binders shall be

stored with appropriate circulation or agitation
facility, according to the manufacturer’s instructions.
Modified binder supplied for the Contract

shall be paid for in Tonnes.
Page 549 of 1427

(TREATED WITH MODIFIED
CRUMB RUBBER)
Designation Grade
CRMB CRMB CRMB
60 55 50
Penetration at 25°C, 0.1mm, 100g, 50 - 70 50 - 60 40 - 60
5 sec.
Minimum
ElasticRecovery of Half Thread in 40 35 30
Ductilometer at 15°C, %,
Minimum
TFOT(IS:9382-1979)
%, Maximum
Maximum
in Ductilometer at 15°C, %,
Minimum
CRMB-Crumb Rubber Modified Bitumen
521.7 Rate
The contract rate for modified binder shall be

as per contract agreement.
Page 550 of 1427

522. CRACK PREVENTION COURSES1
522.1. Scope
This clause covers the provision of Stress

Absorbing Membrane (SAM) and Stress Absorbing
Membrane Interlayer (SAMI) as measures to inhibit
the propagation of cracks. A SAM is an elastomeric
bitumen rubber membrane, which is laid over a
cracked road surface, together with a covering of
aggregate chips, in order to extend the life of the
pavement before major treatment is carried out.
SAM can be laid as a single coat or a double coat. A
SAMI is a layer which is applied to a cracked
pavement surface but which is followed (within 12
months) by the application of an overlay course. A
SAMI may be a material similar to that used for a
SAM. It may alternatively consist of a bitumen
impregnated geotextile.
522.2. Materials
1
DG(RD), Ministry of Road Transport & Highways,
Transport Bhavan, Parliament Street, New Delhi -
110 001. Fax No. # 3710236.
Page 551 of 1427

522.2.1. Binder: Binder shall be a modified
binder complying with the requirements of Clause
523, according to the requirements of the Contract,
except that paving grade bitumen of 80-100
penetration complying with the requirements of
IS:73 shall be used in the case of a bitumen
impregnated geotextile.
522.2.2. Aggregate: The requirements of

Clause 510.2.2 apply except that the Polished Stone
Value requirement does not apply in the case of a
SAMI. Where required by the contract, aggregate
shall be pre-coated using either of the techniques
permitted by Clause 510.2.5.
522.2.3. Rates of spread of binder and

aggregate: The rates of spread of binder and
aggregate shall be according to one of the size
alternatives in Table 500-47, as required by the
Contract.
522.2.4. Geotextile: The use of geotextile as

prescribed for SI. No. 7 in Table 500-47 shall
conform to the requirements of Clause 703.3.


which the SAM, SAMI or bitumen impregnated
Page 552 of 1427

geotextile is to be laid shall be prepared, in
accordance with Clause 501 and as directed by the
Engineer. The surface shall be thoroughly cleaned
either by using a mechanical brush or any other
equipment / method approved by the Engineer. Dust
removed in the process shall be blown off with
compressed air.
522.3.3. Application of binder: The

Supervision of Bituminous Works. The application
temperature for modified binder shall be 160-170°C.
Binder for bitumen impregnated
TABLE 500-47. QUANTITY OF MATERIALS

REQUIRED FOR 10 SO M OF
ROAD SURFACE FOR
STRESS ABSORBING MKMBRANF
SI Type and width of Specification of Quantity Qua

No Crack SAM to be of binder
applied Kg/10m2
1. Hair cracks and map Single coal SAM 8 – 10 0.10m3
nd
cracks upto 3mm width or 2 coat of two
coat SAM
2. Map cracks or alligator Single coat SAM 10 – 12 0.11m3
cracks 3mm lo 6mm
width
3. Map cracks or alligator Two coat SAM 12 – 14 0.12m3
cracks 6mm to 9mm 1st coat 11.2mm
width 2nd coat 8 – 10 0.103 o
Page 553 of 1427

4. Cracks above 9mm Two coat SAM
width and cracked area 1st coat 14 - 16 0.12m3
above 50% 2nd coat 8 - 10 0.103 o
5. All types of cracks with Single coat SAM 8 – 10 0.10m3
Crack width below 6mm as interlayer
6. All types of cracks with Single coat SAM 10 – 12 0.10m3
Crack width below 6mm as interlayer
7. Bitumen Impregnated
Geotextile
Note:1. Binder quantities for bitumen
impregnated geotextile shall be in the range
0.9 to 1.2 litres/nr. Binder quantities
outside this range art permitied
according to the geotextile
manufacturer’s instructions and
subject to the agreement of the
Engineer.
geotextile shall be applied according to Clause

502.4. The surface on which the binder is to be
applied shall be dry.
522.3.4. Application of aggregates : The

Supervision of Bituminous Works. Immediately after
application of the modified binder, clean, dry
aggregate shall be spread uniformly on the surface.
522.3.5. Sweeping : The surface of SAMs

and SAMIs shall be swept to ensure uniform spread
of aggregate and that there are no loose chips on the
Page 554 of 1427

surface.
522.3.6. Two coat SAM or SAMI: Where a

two coat SAM or SAMI is required by the Contract,
the second coat shall be applied within 90 days of
the first.
522.3.7. Geotextile placement: For bitumen

impregnated geotextile, the requirements of Clause
703.4.5
Traffic may be permitted over a SAM or

SAMI 2 hours after rolling, but the speed shall be
limited to 20 km/h, until the following day. Speed
control measures are to be approved by the Engineer,
prior to laying.

of Work
The surface finish shall conform to the

supplied and the works carried out. the relevant

Page 555 of 1427

Each application of SAM, SAMI or bitumen

impregnated geotextile shall be measured as finished
work, for the area specified, in square metres.
Page 556 of 1427

522.8. Rate
The contract unit rate for SAM, SAMI or

bitumen impregnated geotextile shall be payment in
Page 557 of 1427

Concrete Pavement
600
Concrete Pavement
Page 558 of 1427

601. DRY LEAN CEMENT CONCRETE
SUB-BASE
601.1. Scope
601.1.1. The work shall consist of

construction of dry lean concrete subbase for cement
concrete pavement in accordance with the require-
ments of these Specifications and in conformity with
the lines, grades and cross-sections shown on the
drawings or as directed by the Engineer. The work
shall include furnishing of all plant and equipment,
materials and labour and performing all operations,
in connection with the work, as approved by the
Engineer.
601.1.2. The design parameters of dry lean

concrete sub-base, viz., width, thickness, grade of
concrete, details of joints, if any, etc. shall be as
stipulated in the Contract drawings.
601.2. Materials
601.2.1. Source of Materials: The

Contractor shall indicate to the Engineer the source
of all materials with relevant test data to be used in
the lean concrete work sufficiently in advance and
the approval of the Engineer for the same shall be
obtained at least 45 days before the scheduled
commencement of the work. If the Contractor later
proposes to obtain the materials from a different
source, he shall notify the Engineer for his approval
at least 45 days before such materials are to be used.
Page 559 of 1427

601.2.2. Cement: Any of the following types
of cement may be used with prior approval of the
Engineer:
(i) Ordinary Portland Cement
IS : 269
(ii) Portland Slag Cement
IS : 455
(iii) Portland Pozzolana Cement
IS : 1489
If the subgrade is found to consist of soluble

sulphates in a concentration more than 0.5 per cent,
cement used shall be sulphate resistant and shall
conform to IS: 6909.
Cement to be used may preferably be
obtained in bulk form. It shall be stored in
accordance with stipulations contained in Clause
1014 and shall be subjected to acceptance test prior
to its immediate use.
601.2.3. Aggregates:
601.2.3.1. Aggregates for lean concrete shall

be natural material complying with IS: 383. The
aggregates shall not be alkali reactive. The limits of
deleterious materials shall not exceed the
requirements set out in IS : 383. In case the Engineer
considers that the aggregates are not free from din,
the same may be washed and drained for at least 72
hours before batching, as directed by the Engineer.
Page 560 of 1427

601.2.3.2. Coarse aggregate: Coarse
aggregate shall consist of clean, hard, strong, dense,
non-porous and durable pieces of crushed stone or
crushed gravel and shall be devoid of pieces of
disintegrated stone, soft, flaky, elongated, very
angular or splintery pieces. The maximum size of the
coarse aggregate shall be 25 mm. The coarse
aggregate shall comply with Clause 602.2.4.2.
Page 561 of 1427

601.2.3.3. Fine aggregate: The fine
aggregate shall consist of clean, natural sand or
crushed stone sand or a combination of the two and
shall conform to IS : 383. Fine aggregate shall be
free from soft particles, clay, shale, loam, cemented
particles, mica, organic and other foreign matter. The
fine aggregate shall comply with Clause 602.2.4.3.
601.2.3.4. The coarse and fine aggregates

may be obtained in either of the following manner:
(i) In separate nominal sizes of coarse
and fine aggregates and mixed
together intimately before use.
(ii) Separately as 25 mm nominal single
size, 12.5 mm nominal size graded
aggregates and fine aggregate of
crushed stone dust or sand or a
combination of these two.
The material after blending shall conform to
the grading as indicated in Table 600-1.

FOR DRY LEAN CONCRETE
Sieve Designation Percentage passing the

sieve by weight
26.50mm 100
19.00mm 80-100
9.50mm 55-75
4.75mm 35-60
600.00 micron 10-35
75.00 micron 0-8
Page 562 of 1427

601.2.4. Water: Water used for mixing and
curing of concrete shall be clean and free from
injurious amounts of oil, salt, acid, vegetable matter
or other substances harmful to the finished concrete.
It shall meet the requirements stipulated in IS : 456.
601.2.5. Storage of materials: All materials

shall be stored in accordance with the provisions of
Clause 1014 of these Specifications and other
relevant IS Specifications. All efforts must be made
to store the materials in proper places so as to
prevent their deterioration or contamination by
foreign matter and to ensure their satisfactory quality
and fitness for use in the work. The storage place
must also permit easy inspection, removal and
storage of materials. All such materials even though
stored in approved godowns must be subjected to
acceptance test immediately prior to their use. The
requirement of storage yard specified in Clause
602.2.9 shall also be applicable.
601.3. Proportioning of Materials for the

Mix
601.3.1. The mix shall be proportioned with

a maximum aggregate cement ratio of 15:1. The
water content shall be adjusted to the optimum as
per Clause 601.3.2 for facilitating compaction by
rolling. The strength and density requirements of
concrete shall be determined in accordance with
Clause 601.6 by making trial mixes.
Page 563 of 1427

601.3.2. Moisture content: The right amount
of water for the lean concrete in the main work shall
be decided so as to ensure full compaction under
rolling and shall be assessed at the time of rolling the
trial length. Too much water will cause the lean
Page 564 of 1427

concrete to be heaving up before the wheels and
picked up on the wheels of the roller and too little
will lead to inadequate compaction, a low in-situ
strength and an open- textured surface.
The optimum water content shall be
determined and demonstrated by rolling during trial
length construction and the optimum moisture
content and degree of compaction shall be got
approved from the Engineer. While laying in the
main work, the lean concrete shall have a moisture
content between the optimum and optimum +2 per
cent, keeping in view the effectiveness of
compaction achieved and to compensate for
evaporation losses.
601.3.3. Cement content: The minimum

cement content in the lean concrete shall not be less
than 150 kg/cu.m. of concrete. If this minimum
cement content is not sufficient to produce concrete
of the specified strength, it shall be increased as
necessary without additional cost compensation to
the Contractor.
601.3.4. Concrete strength: The average

compressive strength of each consecutive group of 5
cubes made in accordance with Clause 903.5.1.1
shall not be less than 10 MPa at 7 days. In addition,
the minimum compressive strength of any individual
cube shall not be less than 7.5 MPa at 7 days. The
design mix complying with the above Clauses shall
be got approved from the Engineer and demonstrated
in the trial length construction.
Page 565 of 1427

601.4. Subgrade
The subgrade shall conform to the grades and

cross sections shown on the drawings and shall be
uniformly compacted to the design strength in
accordance with these Specifications and
Specification stipulated in the Contract. The lean
concrete subbase shall not be laid on a subgrade
softened by rain after its final preparation; surface
trenches and soft spots, if any, must be properly
back-filled and compacted to avoid any weak or soft
spot. As far as possible, the construction traffic shall
be avoided on the prepared subgrade. A day before
placing of the sub-base, the subgrade surface shall be
given a fine spray of water and rolled with one or
two passes of a smooth wheeled roller after a lapse
of 2-3 hours in order to stabilise loose surface. If
Engineer feels it necessary, another fine spray of
water may be applied just before placing sub-base.
601.5. Construction
601.5.1. General: The pace and programme

of the lean concrete sub-base construction shall be
matching suitably with the programme of
construction of the cement concrete pavement over
it. The sub-base shall be overlaid with cement
concrete pavement only after 7 days after sub-base
construction.
601.5.2. Batching and mixing: The batching
Page 566 of 1427

plant shall be capable of proportioning the
materials by weight, each type of material being
weighed separately in accordance with Clause
602.9.3.2. The cement from the bulk stock shall be
weighed separately from the aggregates. The
capacity of batching and mixing plant shall be at
least 25 per cent higher than the proposed capacity
for the laying arrangements. The batching and
mixing shall be carried out preferably in a forced
action central batching and mixing plant having
necessary automatic controls to ensure accurate
proportioning and mixing. Other types of mixers
shall be permitted subject to demonstration of their
Page 567 of 1427

satisfactory performance during the trial length. The
type and capacity of the plant shall be got approved
by the Engineer before commencement of the trial
length. The weighing balances shall be calibrated by
weighing the aggregates, cement, water and
admixtures physically either by weighing with large
weighing machine or in a weigh bridge. The
accuracy of weighing scales of the batching plant
shall be within ± 2 per cent in the case of aggregates
and ±1 percent in the case of cement and water.
The design features of Batching Plant should
be such that the shifting operations of the plant will
not take very long time when they are to be shifted
from place to place with the progress of the work.
601.5.3. Transporting: Plant mix lean

concrete shall be discharged immediately from the
mixer, transported directly to the point where it is to
be laid and protected from the weather by covering
the tippers/ dumpers with tarpaulin during transit.
The concrete shall be transported by tipping trucks,
sufficient in number to ensure a continuous supply of
material to feed the laying equipment to work at a
uniform speed and in an uninterrupted manner. The
lead of the batching plant to paving site shall be such
that the travel time available from mixing to
paving as specified in Clause 601.5.5.2 will be
adhered to.
601.5.4. Placing: Lean concrete shall be

laid/placed by a paver with electronic sensor. The
equipment shall be capable of laying the material in
Page 568 of 1427

one layer in an even manner without segregation, so
that after compaction the total thickness is as
specified. The paving machine shall have high
amplitude tamping bars to give good initial
compaction to the sub-base.
The laying of the two-lane road subbase may
be done either in full width or lane by lane.
Preferably the lean concrete shall be placed and
compacted across the full width of the road, by
constructing it in one go or in two lanes running
forward simultaneously. Transverse and longitudinal
construction joints shall be staggered by 500-1000
mm and 200-400 mm respectively from the
corresponding joints in the overlaying concrete
slabs.
601.5.5. Compaction
601.5.5.1. The compaction shall be carried

out immediately after the material is laid and
levelled. In order to ensure thorough compaction
which is essential, rolling shall be continued on the
full width till there is no further visible movement
under the roller and the surface is closed. The
minimum dry density obtained shall be 97 per cent
of that achieved during the trial length construction
vide Clause 601.7. The densities achieved at the
edges i.e 0.5m from the edge shall not be less than
95 per cent of that achieved during the trial
construction vide Clause 601.7.
601.5.5.2. The spreading, compacting and
Page 569 of 1427

finishing of the lean concrete shall be carried out as
rapidly as possible and the operation shall be so
arranged as to ensure that the time between the
mixing of the first batch of concrete in any
transverse section of the layer and the final finishing
of the same shall not exceed 90 minutes when the
concrete temperature is above 25 and below 30
degree Celsius and 120 minutes if less than 25
degree Celsius. This period may be reviewed by the
Engineer in the light of the results of the trial run but
in no case shall it exceed 2 hours. Work shall not
proceed when the temperature of the concrete
exceeds 30 degree Celsius. If necessary, chilled
water or addition of ice may be resorted to for
bringing down the temperature. It is desirable to stop
concreting when the ambient temperature is above
35°C. After compaction has been
Page 570 of 1427

completed, roller shall not stand on the compacted
surface for the duration of the curing period except
during commencement of next day’s work near the
location where work was terminated the previous
day.
601.5.5.3. Double drum smooth-wheeled

vibratory rollers of minimum 80 to 100 kN static
weight are considered to be suitable for rolling dry
lean concrete. In case any other roller is proposed,
the same shall be got approved from the Engineer,
after demonstrating its performance. The number of
passes required to obtain maximum compaction
depends on the thickness of the lean concrete, the
compactibility of the mix, and the weight and type of
the roller etc., and the same as well as the total
requirement of rollers for the job shall be determined
during trial run by measuring the in-situ density and
the scale of the work to be undertaken.
601.5.5.4. In addition to the number of passes

required for compaction there shall be a preliminary
pass without vibration to bed the lean concrete down
and again a final pass without vibration to remove
roller marks and to smoothen the surface.
Special care and attention shall be exercised
during compaction near joints, kerbs, channels, side
forms and around gullies and manholes. In case
adequate compaction is not achieved by the roller at
these points, use of plate vibrator shall be made, if so
Page 571 of 1427

601.5.5.5. The final lean concrete surface on
completion of compaction and immediately before
overlaying, shall be well closed, free from
movement under roller and free from ridges, low
spots, cracks, loose material, pot holes, ruts or other
defects. The final surface shall be inspected
immediately on completion and all loose, segregated
or defective areas shall be corrected by using fresh
lean concrete material laid and compacted as per
Specification. For repairing honeycombed surface,
concrete with aggregates of size 10 mm and below
shall be spread and compacted. It is necessary to
check the level of the rolled surface for compliance.
Any level/thickness deficiency should be corrected
after applying concrete with aggregates of size 10
mm and below after roughening the surface.
Similarly the surface regularity also should be
checked with 3m straight edge. The deficiency
should be made up with concrete with aggregates of
size 10 mm and below.
601.5.5.6. Segregation of concrete in the

dumpers shall be controlled by premixing each
fraction of the aggregates before loading in the bin
of the batching plant, by moving the dumper back
and forth while discharging the mix on it and
other means. Even paving operation shall such that
the mix does not segregate.
601.5.6. Joints: Contraction and longitudinal

joints shall be provided as per the drawing.
At longitudinal or transverse construction
Page 572 of 1427

joints, unless vertical forms are used, the edge of
compacted material shall be cut back to a vertical
face where the correct thickness of the properly
compacted material has obtained.
601.5.7. Curing: As soon as the lean

concrete surface is compacted, curing shall
commence. One of the following two methods shall
be adopted:
(a) The initial curing shall be done by
spraying with liquid curing
compound. The curing compound
shall be while pigmented or
transparent type with water retention
index of 90 per cent when tested in
accordance with BS 7542. Curing
compound shall be sprayed
immediately after rolling is complete.
As soon as the curing compound has
lost its tackiness, the surface shall be
covered with wet hessian for three
days.
(b) Curing shall be done by covering the
surface by gunny bags/hessian. which
shall be kept continuously moist for 7
days by sprinkling water.
601.6. Trial Mixes
The Contractor shall make trial mixes of dry

lean concrete with moisture contents like 5.0, 5.5,
6.0, 6.5 and 7.0 per cent using cement content
Page 573 of 1427

specified and the specified aggregate grading
but without violating the requirement of aggregate-
cement ratio specified in Clause 601.3.1. Optimum
moisture and density shall be established by
preparing cubes with varying moisture contents.
Compaction of the mix shall be done in three layers
with vibratory hammer fitted with a square or
rectangular foot as described in Clause 903.5.1.1.
After establishing the optimum moisture, a set of six
cubes shall be cast at that moisture for the
determination of compressive strength on the 3rd
and the seventh day. Trial mixes shall be repeated if
the strength is not satisfactory either by increasing
cement content or using higher grade of cement.
After the mix design is approved, the Contractor
shall construct a trial section in accordance with
Clause 601.7.
If during the construction of the trial length,
the optimum moisture content determined as above
is found to be unsatisfactory, the Contractor may
make suitable changes in the moisture content to
achieve a satisfactory mix. The cube specimens
prepared with the changed moisture content should
satisfy the strength requirement. Before production
of the mix, natural moisture content of the aggregate
should be determined on a day-to-day basis so that
the moisture content could be adjusted. The mix
finally designed should neither stick to the rollers,
nor become too dry resulting in ravelling of surface.
601.7. Trial Length
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601.7.1. The trial length shall be constructed
at least 14 days in advance of the proposed date of
commencement of work. At least 30 days prior to the
construction of the trial length, the Contractor shall
submit for the Engineer’s approval a “Method
Statement” giving detailed description of the
proposed materials, plant, equipment, mix
proportion, and procedure for batching, mixing,
laying, compaction and other construction
procedures. The Engineer shall also approve the
location and length of trial construction which shall
be a minimum of 60 m length and for full width of
the pavement. The trial length shall contain the
construction of at least one transverse construction
joint involving hardened concrete and freshly laid
sub-base. The construction of trial length will be
repeated till the Contractor proves his ability to
satisfactorily construct the subbase.
601.7.2. In order to determine and

demonstrate the optimum moisture content which
results in the maximum dry density of the mix
compacted by the rolling equipment and the
minimum cement content that is necessary to
achieve the strength stipulated in the drawing, trial
mixes shall be prepared as per Clause 601.6.
601.7.3. After the construction of the trial

length, the in-silu density of the freshly laid
material shall be determined by sand replacement
method with 20 cm dia
Page 575 of 1427

density cone. Three density holes shall be made at
locations equally spaced along a diagonal that
bisects the trial length; average of these densities
shall be determined. These main density holes shall
not be made in the strip 50 cm from the edges. The
average density obtained from the three samples
collected shall be the reference density and is
considered as 100 per cent. The field density of
regular work will be compared with this reference
density in accordance with Clause 601.5.5.1 and
903.5.1.2. A few cores may be cut as per the
instructions of the Engineer to check segregation or
any other deficiency.
601.7.4. The hardened concrete shall be cut

over 3 m width and reversed to inspect the bottom
surface for any segregation taking place. The trial
length shall be constructed after making necessary
changes in the gradation of the mix to eliminate
segregation of the mix. The lower surface shall not
nave honey-combing and the aggregates shall not be
held loosely at the edges.
601.7.5. The trial length shall be outside the

main works. The main work shall not start until the
trial length has been approved by the Engineer. After
approval has been given, the materials, mix
proportions, moisture content, mixing, laying,
compaction plant and construction procedures shall
not be changed without the approval of the
Engineer.
Page 576 of 1427

601.8. Tolerances for Surface Regularity, Level,
Thickness, Density and Strength
The tolerances for surface regularity, level,

thickness, density and strength shall conform to the
requirements given in Clause 903.5. Control of
quality of materials and works shall be exercised by
the Engineer in nee with Section 900.
601.9. Traffic
No heavy commercial vehicles like trucks

and buses shall be permitted on the lean concrete
sub-base after its construction. Light vehicles if
unavoidable may, however, be allowed after 7 days
of its construction with prior approval of the
Engineer.
The unit of measurement for dry lean

concrete pavement shall be the cubic metre of
concrete placed, based on the net plan areas for
the Specified thickness shown on the drawings or as
601.11. Rate
The Contract unit rate payable for dry lean

concrete sub-base shall be payment in full for
compensation forall labour, materials and
Page 577 of 1427

equipment, mixing, transport placing, compacting,
finishing, curing, testing and incidentals to complete
the work as per Specifications, all royalties, fees,
storage and rents where necessary and all leads and
lifts.
Page 578 of 1427

602. CEMENT CONCRETE PAVEMENT
602.1. Scope

construction of unreinforced, dowel jointed, plain
cement concrete pavement in accordance with the
requirements of these Specifications and in
conformity with the lines grades and cross sections
shown on the drawings. The work shall include
furnishing of all plant and equipment, materials and
labour and performing all operations in connection
with the work, as approved by the Engineer.
602.1.2. The design parameters, viz.,

thickness of pavement slab, grade of concrete, joint
details etc. shall be as stipulated in the drawings.
602.2. Materials
602.2.1. Source of materials: The

of all materials to be used in the concrete work with
relevant test data sufficiently in advance, and the
approval of the Engineer for the same shall be
obtained at least 45 days before the scheduled
proposes to obtain materials from a different source,
he shall notify the Engineer for his approval, at
least 45 days before such materials are to be used
with relevant test data.
Page 579 of 1427

602.2.2. Cement : Any of the following
types of cement capable of achieving the design
strength may be used with prior approval of the
Engineer, but the preference should be to use at least
the 43 Grade or higher.
(i) Ordinary Portland Cement, 33 Grade,
IS : 269.
(ii) Ordinary Portland Cement, 43 Grade
IS : 8112.
(iii) Ordinary Portland Cement, 53 Grade,
IS : 12269.
If the soil around has soluble salts like
sulphates in excess of 0.5 per cent, the cement used
shall be sulphate resistant and shall conform to IS:
12330.
Guidance may be taken from IS: SP: 23,
Handbook for Concrete Mixes for ascertaining the
minimum 7 days strength of cement required .to
match with the design concrete strength. Cement to
be used may preferably be obtained in bulk form. If
cement in paper bags are proposed to be used, there
shall be bag-splitters with the facility to separate
pieces of paper bags and dispose them of suitably.
No paper pieces shall enter the concrete mix. Bulk
cement shall be stored in accordance with Clause
1014. The cement shall be subjected to acceptance
test just prior to its use.
602.2.3. Admixtures: Admixtures

conforming to IS:6925 and IS: 9103 shall be
permitted to improve workability of the concrete or
extension of setting time, on satisfactory evidence
Page 580 of 1427

that they will not have any adverse effect on the
properties of concrete with .respect to strength,
volume change, durability and have no deleterious
effect on steel bars. The particulars of the admixture
and the quantity to be used, must be furnished to the
Engineer in advance to obtain his approval before
use. Satisfactory performance of the admixtures
should be proved both on the laboratory concrete
trial mixes and in trial paving works. If air entraining
admixture is used, the total quantity of air in air-
entrained concrete as a percentage of the volume of
the mix shall be 5 ± 1.5 per cent for 25 mm nominal
size aggregate.
Page 581 of 1427

602.2.4. Aggregates
602.2.4.1. Aggregates for pavement concrete

shall be natural material complying with IS : 383 but
with a Los Angeles Abrasion Test result not more
than 35 per cent The limits of deleterious materials
shall not exceed the requirements set out in IS : 383.
The aggregates shall be free from chert, flint,
chalcedony or other silica in a form that can react
with the alkalies in the cement. In addition, the total
chlorides content expressed as chloride ion content
shall not exceed 0.06 per cent by weight and the total
sulphate content expressed as sulphuric anhydride
(SO3) shall not exceed 0.25 per cent by weight.
602.2.4.2. Coarse aggregate: Coarse

aggregate shall consist of clean, hard, strong, dense,
angular or splintery pieces. The maximum size of
coarse aggregate shall not exceed 25 mm for
pavement concrete. Continuously graded or gap
graded aggregates may be used, depending on the
grading of the fine aggregate. No aggregate which
has water absorption more than 2 per cent shall be
used in the concrete mix. The aggregates shall be
tested for soundness in accordance with IS : 2386
(Part-5). After 5 cycles of testing the loss shall not
be more than 12 per cent if sodium sulphate solution
is used or 18 per cent if magnesium sulphate solution
is used.
Page 582 of 1427

Dumping and stacking of aggregates shall be
done in an approved manner. In case the Engineer
considers that the aggregates are not tree from dirt,
hours before batching as directed by the Engineer.
602.2.4.3. Fine aggregate: The fine

aggregate shall consist of clean natural sand or
shall conform to IS : 383. Fine aggregate shall be
particles, mica and organic and other foreign matter.
The fine aggregate shall not contain deleterious
substances more than the following :
Clay lumps
4.0 per cent
Coal and lignite
1.0 per cent
Material passing IS Sieve No. 75 micron
4.0 per cent

injurious amount of oil, salt, acid, vegetable matter
It shall meet the requirements stipulated in IS: 456.
602.2.6. Mild steel bars for dowels and tie

bars : These shall conform to the requirements of
IS : 432, IS : 1139 and IS : 1786 as relevant. The
dowel bars shall conform to Grade S 240 and tie bars
to Grade S 415 of I.S.
Page 583 of 1427

602.2.7. Premoulded joint filler: Joint filler
board for expansion joints which are proposed for
use only at some abutting structures like bridges and
culverts shall be of 20-25 mm thickness within a
tolerance of ± 1.5 mm and of a firm compressible
material and complying With the requirements of IS:
1838, or BS Specification Clause No.2630 or
Specification for Highway Works, Vol.1 Clause
1015. It shall be 25 mm less in depth than the
thickness of the slab within a tolerance of ± 3 mm
and provided to the full width between the side
forms. It shall be in suitable lengths which shall not
be less than one lane width. Holes to accommodate
dowel bars shall be accurately bored or punched out
to
Page 584 of 1427

give a sliding fit on the dowel bars.
602.2.8. Joint sealing compound: The joint

sealing compound shall be of hot poured,
elastomeric type or cold polysulphide type having
flexibility, resistance to age hardening and
durability. If the sealant is of hot poured type it shall
conform to AASHTO M282 and cold applied sealant
shall be in accordance with BS 5212 (Part 2).

Clause 1014 of the Specifications and other relevant
IS Specifications. All efforts must be made to store
the materials in proper places so as to prevent their
deterioration or contamination by foreign matter
and to ensure their satisfactory quality and fitness for
the work. The platform where aggregates are stock
piled shall be levelled with 15 cm of watered, mixed
and compacted granular sub-base material. The area
shall have slope and drain to drain off rain water.
The storage space must also permit easy inspection,
removal and storage of the materials. Aggregates of
different sizes shall be stored in partitioned stack-
yards. All such materials even though stored in
approved godowns must be subjected to acceptance
test as per Clause 903 of these Specifications
immediately prior to their use.
602.3. Proportioning of Concrete
602.3.1. After approval by the Engineer of all
Page 585 of 1427

the materials to be used in the concrete, the
Contractor shall submit the mix design based on
weighed proportions of all ingredients for the
approval of the Engineer. The mix design shall be
submitted at least 30 days prior to the paving of trial
length and the design shall be based on laboratory
trial mixes using the approved materials and
methods as per 18:10262 (Recommended Guidelines
for Mix Design) or on the basis of any other rational
method agreed to by the Engineer. Guidance in this
regard can also be obtained from IS:SP:23
Handbook on Concrete Mixes. The target mean
strength for the design mix shall be determined as
indicated in Clause 903.5.2. The mix design shall be
based on the flexural strength of concrete.
602.3.2. Cement content: The cement

content shall not be less than 350 kg per cu.m. of
concrete. If this minimum cement content is not
sufficient to produce in the field, concrete of the
strength specified in the drawings/design, it shall be
increased as necessary without additional
compensation under the Contract. The cement
content shall, however, not exceed 425 kg per cu.m.
of concrete.
602.33. Concrete strength
602.3.3.1. While designing the mix in the

laboratory, correlation between flexural and
compressive strengths of concrete shall be estab-
lished on the basis of at least thirty tests on samples.
Page 586 of 1427

However, quality control in the field shall be
exercised on the basis of flexural strength. It may,
however, be ensured that the materials and mix
proportions remain substantially unaltered during the
daily concrete production. The water content shall be
the minimum required to provide the agreed
workability for full compaction of the concrete to the
required density as determined by the trial mixes or
other means approved by the Engineer and the
maximum free water cement ratio shall be 0.50.
Page 587 of 1427

602.3.3.2. The ratio between the 7 and 28 day
strengths shall be established for the mix to be used
in the slab in advance, by testing pairs of beams and
cubes at each stage on at least six batches of trial
mix. The average strength of the 7 day cured
specimens shall be divided by the average strength
of the 28 day specimens for each batch, and the ratio
‘R’ shall be determined. The ratio ‘R’ shall be
expressed to three decimal places.
If during the construction of the trial length
or during normal working, the average value of any
four consecutive 7 day test results falls below the
required 7 day strength as derived from the value of
‘R’, then the cement content of the concrete shall
without extra payment, be increased by 5 per cent by
weight or by an amount agreed by the Engineer. The
increased cement content shall be maintained at least
until the four corresponding 28 day strengths have
been assessed for its conformity with the
requirements as per Clause 602.3.1. Whenever the
cement content is increased, the concrete mix shall
be adjusted to maintain the required workability.
602.3.4. Workability
602.3.4.1. The workability of the concrete at

the point of placing shall be adequate for the
concrete to be fully compacted and finished without
undue flow. The optimum workability for the mix to
suit the paving plant being used shall be determined
by the Contractor and by the Engineer. The control
of workability in the field shall be exercised by the
Page 588 of 1427

slump test as per IS : 1199.
602.3.4.2. The workability requirement at the

Batching Plant, and paving site shall be established
by slump tests carried during trial paving. These
requirements shall be established from season to
season and also the lead from Batching plant site to
the paving site changes. The workability shall be
established for the type of paving equipment avail-
slump value in the range of 30 ± 15 mm is
reasonable for paving works but this may be
modified depending upon the site requirement and
got approved by the Engineer. These tests shall be
carried out on every Truck/dumper at Plant site and
paving site initially when the work commences but
subsequently the frequency can be reduced to
alternate truck or as per the instructions of the
Engineer.
602.3.5. Design mix
602.3.5.1. The Contractor shall carry out

laboratory trials of design mixes with the materials
from the approved sources to be used. Trial mixes
shall be made in presence of the Engineer or his
representative and the design mix shall be subject to
the approval of the Engineer. They shall be repeated
if necessary until the proportions that will produce a
concrete which complies in all respects with this
Specification, and conforms to the requirement of
the design/drawings have been determined.
Page 589 of 1427

602.3.5.2. The proportions determined as a
result of the laboratory trial mixes may be adjusted if
necessary during the construction of the trial length.
Thereafter, neither the materials nor the mix
proportions shall be varied in any way except with
the written approval of the Engineer.
602.3.5.3. Any change in the source of

materials or mix proportions proposed by the
Contractor during the course of work shall be
assessed by making laboratory trial mixes and the
construction of a further trial length unless approval
is given by the
Page 590 of 1427

Engineer for minor adjustments like compensation
for moisture content in aggregates or minor fluctua-
tions in the grading of aggregate.
602.4. Sub-base
The cement concrete pavement shall be laid

over the sub-base constructed in accordance with the
relevant drawings and Specifications contained in
Clause 601. If the sub-base is found damaged at
some places or it has cracks wider than 10 mm, it
shall be repaired with fine cement concrete or
bituminous concrete before laying separation layer.
Prior to laying of concrete it shall be ensured that the
separation membrane as per Clause 602.5 is placed
in position and the same is clean of dirt or other
extraneous materials and free from any damage.
602.5. Separation Membrane
A separation membrane shall be used

between the concrete slab and the subbase.
Separation membrane shall be impermeable plastic
sheeting 125 microns thick laid flat without creases.
Before placing the separation membrane, the sub-
base shall be swept clean of all the extraneous
materials using air compressor. Wherever overlap of
plastic sheets is necessary, the same shall be at least
300 mm and any damaged sheeting shall be replaced
at the Contractor’s expense. The separation
membrane may be nailed to the lower layer with
concrete nails.
Page 591 of 1427

602.6. Joints
602.6.1. The location and type of joints shall

be as shown in the drawing. Joints shall be
constructed depending upon their functional
requirement as detailed in the following paragraphs.
The location of the joints should be transferred
accurately at the site and mechanical saw cutting of
joints done as per stipulated dimensions. It should be
ensured that the full required depth of cut is made
from edge to edge of the pavement. Transverse and
longitudinal joints in the pavement and sub-base
shall be staggered so that they are not coincident
vertically and are at least 1m and 0.3m apart
respectively. Sawing of joints shall be carried out
with diamond studded blades soon after the concrete
has hardened to take the load of the sawing machine
and personnel without, damaging the texture of the
pavement. Sawing operation could start as early as
6-8 hours depending upon the season.
602.6.2. Transverse joints
602.6.2.1. Transverse joints shall be

contraction and expansion joints constructed at the
spacing described in the Drawings. Transverse joints
shall be straight within the following tolerances
along the intended line of joints which is the straight
line transverse to the longitudinal axis of the
carriageway at the position proposed by the
Contractor and agreed to by the Engineer, except at
Page 592 of 1427

road junctions or roundabouts where the position
shall be as described in the drawings:
(i) Deviations of the filler board in the
case of expansion joints from the
intenaed line of the joint shall not be
greater than ±10 mm.
(ii) The best fit straight line through the
joint grooves as constructed shall be
not more than 25 mm from the
intended line of the joint.
Page 593 of 1427

(iii) Deviations of the joint groove from
the best fit straight line of the joint
shall not be greater than 10 mm.
(iv) Transverse joints on each side of the
longitudinal joint shall be in line
with each other and of the same type
and width. Transverse joints shall
have a sealing groove which shall be
sealed in compliance with Clause
602.11.
602.6.2.2. Contraction joints : Contraction
joints shall consist of a mechanical sawn joint
groove, 3 to 5 mm wide and 1/4 to 1/3 depth of the
slab ± 5 mm or as stipulated in the drawings and
dowel bars complying with Clause 602.6.5 and as
detailed in the drawings.
The contraction joints shall be cut as soon as
the concrete has undergone initial hardening and is
hard enough to take the load of joint sawing machine
without causing damage to the slab.
602.6.2.3. Expansion joints: The expansion

joints shall consist of a joint filler board complying
with Clause 602.2.7 and dowel bars complying with
Clause 602.6.5 and as detailed in the drawings. The
filler board shall be positioned vertically with the
prefabricated joint assemblies along the line of the
joint within the tolerances given in Clause 602.6.2.1.
and at such depth below the surface as will not
impede the passage of the finishing straight edges or
oscillating beams of the paving machines. The
adjacent slabs shall be completely separated from
Page 594 of 1427

each other by providing joint filler board. Space
around the dowel bars, between the sub-base and the
filler board shall be packed with a suitable
compressible material to block the flow of cement
slurry.
602.6.3. Transverse construction joint:

Transverse construction joints shall be placed
whenever concreting is completed after a day’s work
or is suspended for more than 30 minutes. These
joints shall be provided at the regular location of
contraction joints using dowel bars. The joint shall
be made butt type. At all construction joints, steel
bulk heads shall be used to retain the concrete while
the surface is finished. The surface of the concrete
laid subsequently shall conform to the grade and
cross sections of the previously laid pavement. When
positioning of bulk head/ stop-end is not possible,
concreting to an additional 1 or 2 m length may be
carried out to enable the movement of joint cutting
machine so that joint grooves may be formed and
the extra 1 or 2 m length is cut out and removed
subsequently after concrete has hardened.
602.6.4. Longitudinal joint
602.6.4.1. The longitudinal joints shall be

saw cut as per details of the joints shown in the
drawing. The groove may be cut after the final set of
the concrete. Joints should be sawn to at least 1/3 the
depth of the slab ± 5 mm as indicated in the drawing.
Page 595 of 1427

602.6.4.2. Tie bars shall be provided at the
longitudinal joints as per dimensions and spacing
shown in the drawing and in accordance with Clause
602.6.6.
602.6.5. Dowel bars
602.6.5.1. Dowel bars shall be mild steel

rounds in accordance with Clause 602.2.6 with
details/dimensions as indicated in the drawing and
free from oil, dirt, loose rust or scale. They shall be
straight, free of irregularities and burring restricting
slippage in the concrete. The sliding ends shall be
sawn or cropped cleanly with no protrusions
Page 596 of 1427

outside the normal diameter of the bar. The dowel
bar shall be supported on cradles/dowel chairs in
pre-fabricated joint assemblies positioned prior to
the construction of the slabs or mechanically inserted
with vibration into the plastic concrete by a method
which ensures correct placement of the bars besides
full re-compaction of the concrete around the dowel
bars.
602.6.5.2. Unless shown otherwise on the

drawings, dowel bars shall be positioned at mid
depth of the slab within a tolerance of ± 20 mm, and
centered equally about intended lines of the joint
within a tolerance of ± 25 mm. They shall be aligned
parallel to the finished surface of the slab and to the
centre line of the carriagev ay and to each other
within tolerances given hereunder, the compliance of
which shall be checked as per Clause 602.10.7.
(i) For bars supported on cradles prior to
the laying of the slab:
(a) All bars in a joint shall be
within ± 3 mm per 300 mm length of bar
(b) 2/3rd of the bars shall be
within ±2 mm per 300 mm length of bar
(c) No bar shall differ in
alignment from an adjoining bar by
more
than 3mm per 300 mm
length of bar in either the
horizontal or vertical plane
(d) Cradles supporting dowel bar
shall not extend across the line
Page 597 of 1427

of joint i.e. no steel bar of the
cradle assembly shall be
continuous across the joint.
(ii) For all bars inserted after laying of
the slab:
(a) Twice the tolerance for
alignment as indicated in (i) above
602.6.5.3. Dowel bars, supported on cradles

in assemblies, when subject to a load of 110 N
applied at either end and in either the vertical or
horizontal direction (upwards and downwards and
both directions horizontally) shall conform to be
within the following limits:
(i) Two-thirds of the number of bars of
any assembly tested shall not deflect
more than 2 mm per 300 mm length
of bar
(ii) The remainder of the bars in that
assembly per 300 mm length of bar.
shall not deflect more than 3 mm
602.6.5.4. The assembly of dowel bars and

supporting cradles, including the joint filler board in
the case of expansion joints, shall ‘have the
following degree of rigidity when fixed in position:-
(i) For expansion joints, the deflection of
the top edge of the filler board shall
be not greater than 13 mm, when a
load of 1.3 kN is applied
perpendicular to the vertical face of
the joint filler board and distributed
Page 598 of 1427

over a length of 600 mm by means of
a bar or timber packing, at mid depth
and midway between individual
fixings, or 300 mm from either end
of any length of filler board, if a
continuous fixing is used. The
residual deflection after removal of
the load shall be not more than 3
mm.
(ii) The joint assembly fixings to sub-
base shall not fail under the 1.3kN
load applied for testing the rigidity of
the assembly but shall fail before the
load reaches 2.6 kN.
(iii) The fixings for contraction joint shall
not fail under 1.3 kN load and shall
fail before the load reaches 2.6 kN
when applied over a length of 600
mm by means of a bar or timber
packing placed as near to the level of
the line of fixings as practicable.
Page 599 of 1427

(iv) Fixings shall be deemed to fail when
there is displacement of the
assemblies by more than 3 mm with
any form of fixing, under the test
load. The displacement shall be
measured at the nearest pan of the
assembly to the centre of the bar or
timber packing.
602.6.5.5. Dowel bars shall be covered by a

thin plastic sheath for at least two-thirds of the
length from one end for dowel bars in contraction
joints or half the length plus 50 mm for expansion
joints. The sheath shall be tough, durable and of an
average thickness not greater than 1.25 mm. The
sheathed bar shall comply with the following pull-
out tests:
(i) Four bars shall be taken at random
from stock and without any special
preparation shall be covered by
sheaths as required in this Clause.
The ends of the dowel bars which
have been sheathed shall be cast
centrally into concrete specimens 150
x 150 x 600 mm, made of the same
mix proportions to be used in the
pavement, but with a maximum
nominal aggregate size of 20 mm and
cured in accordance with IS: 516. At
7 days a tensile load shall be applied
to achieve a movement of the bar of
Page 600 of 1427

at least 0.2S mm. The average bond
stress to achieve this movement shall
not be greater than 0.14 MPa.
602.6.5.6. For expansion joints, a closely

fitting cap 100mm long consisting of waterproofed
cardboard or an approved synthetic material like
PVC or GI pipe shall be placed over the sheathed
end of each dowel bar. An expansion space at least
equal in length to the thickness of the joint filler
board shall be formed between the end of the cap
and the end of the dowel bar by using compressible
sponge. To block the entry of cement slurry between
dowel and cap it may be taped.
602.6.6. Tie bars
602.6.6.1. Tie bars in longitudinal joints

shall be deformed steel bars of strength 415 MPa
complying with IS: 1786 and in accordance with the
requirements given below. The bars shall be
free from oil, dirt, loose rust and scale.
602.6.6.2. Tie bars projecting across the

longitudinal joint shall be protected from corrosion
for 75mm on each side of the joint by a protective
coating of bituminous paint with the approval of the
Engineer. The coating shall be dry when the tie bars
are used.
602.6.6.3. Tie bars in longitudinal joints shall

be made up into rigid assemblies with adequate
Page 601 of 1427

supports and fixings to remain firmly in position
during the construction of the slab. Alternatively, tie
bars at longitudinal joints may be mechanically or
manually inserted into the plastic concrete from
above by vibration using a method which ensures
correct placement of the bars and recompaction of
the concrete around the tie bars.
602.6.6.4. Tie bars shall be positioned to

remain within the middle third of the slab depth as
indicated in the drawings and approximately parallel
to the surface and approximately perpendicular to
the line of the joint, with the centre of each baron the
intended line of the joints within a tolerance of ±
50mm, and with a minimum cover of
Page 602 of 1427

30mm below the pint groove.
602.7.1. Concreting during monsoon months:

When concrete is being placed during monsoon
months and when it may be expected to rain,
sufficient supply of tarpaulin or other water proof
cloth shall be provided along the line of the work.
Any time when it rains, all freshly laid concrete
which had not been covered for curing purposes
shall be adequately protected. Any concrete
damaged by rain shall be removed and replaced. If
the damage is limited to texture, it shall be retextured
in accordance with the directives of the Engineer.
602.7.2. Concreting in hot weather: No

concreting shall be done when the concrete
temperature is above 30 degree Centigrade. Besides,
in adverse conditions like high temperature, low
relative humidity, excessive wind velocity,
imminence of rains etc., if so desired by the
Engineer, tents on mobile trusses may be provided
over the freshly laid concrete for a minimum period
of 3 hours as directed by the Engineer. The
temperature of the concrete mix on reaching the
paving site shall not be more than 30° C. To bring
down the temperature, if necessary, chilled water or
ice flakes should be made use of.
No concreting shall be done when the
concrete temperature is below 5 degree Centigrade
and the temperature is descending.
Page 603 of 1427

602.8. Side Forms, Rails and Guide wires
602.8.1. Side forms and rails: All side forms

shall be of mild steel of depth equal to the thickness
of pavement or slightly less to accommodate the
surface regularity of the sub-base. The forms can be
placed on series of steel packing plates or shims to
take care of irregularity of sub-base. They shall be
sufficiently robust and rigid to support the weight
and pressure caused by a paving equipment.
Sideforms for use with wheeled paving machines
shall incorporate metal rails firmly fixed at a
constant height below the top of the forms. The
forms and rails shall be firmly secured in position by
not less than 3 stakes/pins per each 3 m length so as
to prevent movement in any direction. Forms and
rails shall be straight within a tolerance of 3 mm in 3
m and when in place shall not settle in excess of 1.5
mm in 3 m while paving is being done. Form shall
be cleaned and oiled immediately before each use.
The forms shall be bedded on a continuous bed of
low moisture content lean cement mortar or concrete
and set to the line and levels shown on the drawings
within tolerances ± 10 mm and ± 3 mm respectively.
The bedding shall not extend under the slab and
there shall be no vertical step between adjacent
forms of more than 3 mm. The forms shall be got
inspected from the Engineer for his approval before
12 hours on the day before the construction of the
slab and shall not be removed until least 12 hours
afterwards.
Page 604 of 1427

602.8.2. At all times sufficient forms shall be
used and set to the required alignment for at least
200 m length of pavement immediately in advace of
the paving operations, or the anticipated length of
pavement to be laid within the next 24 hrs whichever
is more.
Page 605 of 1427

602.8.3. Use of guidewires
602.8.3.1. Where slip form paving is

proposed, a guidewire shall be avided along both
sides of the slab. Each guidewire shall be at a
constant height above and parallel to the required
edges of the slab as described in the
contract/drawing within a vertical tolerance of ±
3mm. Additionally, one of the wires shall be kept at
a constant horizontal distance from the required edge
of the pavement as indicated in the
contract/drawing within a lateral tolerance of ± 10
mm.
602.8.3.2. The guidewires shall be supported

on stakes net more than 8m apart by connectors
capable of fine horizontal and vertical adjustment.
The guidewire shall be tensioned on the stakes so
that a 500 gram shall produce a deflection of not
more than 20mm when suspended at the mid point
between any pair of stakes. The ends of the
guidewres shall be anchored to fixing point or winch
and not on the stakes.
602.8.3.3. The stakes shall be positioned and

the connectors maintained at their correct height and
alignment from 12 hours on the day before
concreting takes place until 12 hours after finishing
of the concrete. The guidewire shall be erected and
tensioned on the Connectors at any section for at
least 2 hours before concreting that section.
Page 606 of 1427

602.8.3.4. The Contractor shall submit to the
Engineer for his approval of line and level, the stakes
and connectors which are ready for use in the length
of road to be constructed by 12 hours on the working
day before the day of construction of slab. Any
deficiencies noted by the Engineer shall be rectified
by the Contractor who shall then re-apply for
approval of the affected stakes. Work shall not
proceed until the Engineer has given his approval. It
shall be ensured that the stakes and guidewires are
not affected by the construction equipment when
concreting is in progress.
602.9. Construction
602.9.1. General: A systems approach may

be adopted for construction of the pavement, and
the Method Statement for carrying out the work,
detailing all the activities including indication of
time-cycle, equipment, personnel etc., shall be got
approved from the Engineer before the
commencement of the work. The above shall include
the type, capacity and make of the batching and
mixing plant besides the hauling arrangement and
paving equipment. The capacity of paving
equipment, batching plant as well as all the ancillary
equipment shall be adequate for a paving rate of
atleast 300 m in one day.
602.9.2. Batching and mixing: Batching and

mixing of the concrete shall be done at a central
batching and mixing plant with automatic controls,
Page 607 of 1427

located at a suitable place which takes into account
sufficient space for stockpiling of cement,
aggregates and stationary water tanks. This shall
be, however, situtated at an approved distance, duly
considering the properties of the mix and the
transporting arrangements available with the
Contractor.
602.9.3. Equipment for proportioning of

materials and paving
602.9.3.1. Proportioning of materials shall be

done in the batching plant by weight, each type of
material being weighed separately. The cement from
the bulk stock
Page 608 of 1427

may be weighed separately from the aggregates and
water shall be measured by volume. Wherever
properly graded aggregate of uniform quality cannot
be maintained as envisaged in the mix design, the
grading of aggregates shall be controlled by
appropriate blending techniques. The capacity of
batching and mixing plant shall be at least 25 per
cent higher than the proposed capacity of the
laying/paving equipment.
602.9.3.2. Batching plant and equipment:
(1) General- The batching plant shall include

minimum four bins, weighing hoppers, and
scales for the fine aggregate and for each size
of coarse aggregate. If cement is used in
bulk, a separate scale for cement shall be
included. The weighing hoppers shall be
properly sealed and vented to preclude dust
during operation. Approved safety devices
shall be provided and maintained for the
protection of all personnel engaged in plant
operation, inspection and testing. The batch
plant shall be equipped with a suitable non-
resettable batch counter which will correctly
indicate the number of batches proportioned.
(2) Bins and hoppers- Bins with minimum
number of four adequate separate
compartments shall be provided in the
batching plant.
(3) Automatic weighing devices- Batching plant
shall be equipped to proportion
Page 609 of 1427

aggregates and bulk cement by means of
automatic weighing devices using load cells.
(4) Mixers- Mixers shall be pan type, reversible
type or any other mixer capable of combining
the aggregates, cement, and water into a
thoroughly mixed and uniform mass within
the specific mixing period, and of
discharging the mixture, without segregation.
Each stationary mixer shall be equipped with
an approved timing device which will
automatically lock the discharge lever when
the drum has been charged and release it at
the end of the mixing period. The device
shall be equipped with a bell or other suitable
warning device adjusted to give a clearly
audible signal each time the lock is released.
In case of failure of the timing device, the
mixer may be used for the balance of the day
while it is being repaired, provided that each
batch is mixed 90 seconds or as per the
manufacturer’s recommendation. The mixer
shall be equipped with a suitable non-
resettable batch counter which shall correctly
indicate the number of batches mixed.
The mixers shall be cleaned at suitable
intervals. The pickup and throw-over blades
in the drum or drums shall be repaired or
replaced when they are worn down 20 mm or
more. The Contractor shall (1) have available
at the job site a copy of the manufacturer’s
design, showing dimensions and
arrangements of blades in reference to
Page 610 of 1427

original height and depth, or (2) provide
permanent marks on blade to show points of
20 mm wear from new conditions. Drilled
holes of 5 mm diameter near each end and at
midpoint of each blade are recommended.
Batching Plant shall be calibrated in the
beginning and thereafter at suitable interval
not exceeding 1 month.
(5) Control cabin - An air-conditioned
centralised control cabin shall be provided
for automatic operation of the equipment.
602.9.3.3. Paving equipment : The concrete

shall be placed with an approved fixed form or slip
from paver with independent units designed to (i)
spread.(ii) consolidate, screed and float-finish, (iii)
texture and cure the freshly placed concrete in one
complete pass bf the machine in such a manner that a
minimum of hand finishing
Page 611 of 1427

will be necessary and so as to provide a dense and
homogeneous pavement in conformity with the plans
and Specifications. The paver shall be equipped with
electronic controls to control/sensor line and grade
from either or both sides of the machine.
Vibrators shall operate at a frequency of
8300 to 9600 impulses per minute under load at a
maximum spacing of 60 cm. The variable vibration
setting shall be provided in the machine.
602.9.3.4. Concrete saw: The Contractor

shall provide adequate number of concrete saws with
sufficient number of diamond-edge saw blades. The
saw machine shall be either electric or petrol/diesel
driven type. A water tank with flexible hoses and
pump shall be made available in this activity on
priority basis. The Contractor shall have at least one
standby saw in good working condition. The
concreting work shall not commence if the saws are
not in working condition.
602.9.4. Hauling and placing of concrete
602.9.4.1. Freshly mixed concrete from the

central batching and mixing plant shall be
transported to the paver site by means of
trucks/tippers of sufficient capacity and approved
design in sufficient numbers to ensure a constant
supply of concrete. Covers shall be used for
protection of concrete against the weather. The
trucks/tippers shall be capable of maintaining the
mixed concrete in a homogeneous state and
Page 612 of 1427

discharging the same without segregation and loss of
cement slurry. The feeding to the paver is to be
regulated in such a way that the paving is done in an
uninterrupted manner with a uniform speed
throughout the days work.
602.9.4.2. Placing of concrete
Concrete mixed in central mixing plant shall

be transported to the site without delay and the
concrete which, in the opinion of the Engineer, has
been mixed too long before laying will be rejected
and shall be removed from the site. The total time
taken from the addition of the water to the mix, until
the completion of the” surface finishing and
texturing shall not exceed 120 minutes when
concrete temperature is less than 25°C and 90
minutes when the concrete temperature is between
25°C to 30°C. Truck/tipper delivering concrete shall
not run on plastic sheeting nor shall they run on
completed slabs until after 28 days of placing the
concrete. The Paver shall be capable of paying the
carriageway as shown in the drawings, in a single
pass and lift.
602.9.4.3. Where fixed form pavers are to be

used, forms shall be fixed in advance as per Clause
602.8. of the Specifications. Before any paving is
done, the site shall be shown to the Engineer, in
order to verify the arrangement for paving besides
placing of dowels, tie-bars etc., as per the relevant
Clauses of this Specification. The mixing and
Page 613 of 1427

placing of s concrete shall progress only at such a
rate as to permit proper finishing, protecting and
curing of the pavement.
602.9.4.4. In all cases, the temperature of the

concrete shall be measured at the point of discharge
from the delivery vehicle.
602.9.4.5. The addition of water to the

surface of the concrete to facilitate the finishing
operations will not be permitted except with the
approval of the Engineer when it shall be applied as
a mist by means approved equipment.
Page 614 of 1427

602.9.4.6. If considered necessary by the
Engineer, the paving machines shall be provided
with approved covers to protect the surface of the
slab under construction from direct sunlight and rain
or hot wind.
602.9.4.7. While the concrete is still plastic,

its surface shall be brush textured in compliance with
Clause 602.9.8 and the surface and edges of the slab
cured by the application of a sprayed liquid curing
membrane in compliance with Clause 602.9.9. After
the surface texturing, but before the curing
compound is applied, the concrete slab shall be
marked with chainage at every 100 m interval.
602.9.4.8. As soon as the side forms are

removed, edges of the slabs ill be corrected wherever
irregularities have occurred by using fine concrete
composed of one part of cement to 3 parts of fine
chips and aggregate under the supervision of the
Engineer.
602.9.4.9. If the requirement of Clause 902.4.

for surface regularity to be achieved on two
consecutive working days, then normal working
shall cease until the cause of the excessive
irregularity has been identified and remedied.
602.9.5. Construction by fixed form paver
602.9.5.1. The fixed form paving train shall

consist of separate powered machines which spread,
Page 615 of 1427

compact and finish the concrete in continuous
operation.
602.9.5.2. The concrete shall be discharged

without segregation into a hopper spreader which is
equipped with means for controlling its rate of
deposition on to the subbase. The spreader shall be
operated to strike off concrete upto a level requiring
a small amount of cutting down by the distributor of
the spreader. The distributor of spreader shall strike
off the concrete to the surcharge adequate to ensure
that the vibratory compactor thoroughly compacts
the layer. If necessary, poker vibrators shall be used
adjacent to the side forms and edges of the
previously constructed slab. The vibratory
compactor shall be set to strike off the surface
slightly high so that it is cut down to the required
level by the oscillating beam. The machine shall be
capable of being rapidly adjusted for changes in
average and differential surcharge necessitated by
changes in slab thickness or cross fall. The final
finisher shall be able to finish the surface to the
required level and smoothness as specified, care
being taken to avoid bringing up of excessive
mortar to the surface by overworking.
602.9.6. Construction by slip form paver
602.9.6.1. The slip form paving train shall

consist of power machine which spreads, compacts
and finishes the concrete in a continuous operation.
The slip form paving machine shall compact the
Page 616 of 1427

concrete by internal vibration and shape it between
the side forms with either a conforming plate or by
vibrating and oscillating finishing beams. The
concrete shall be deposited without segregation in
front of slip form paver across the whole width and
to a height which at all times is in excess of the
required surcharge. The deposited concrete shall be
struck off to the necessary average and differential
surcharge by means of the strike off plate or a screw
auger device extending across the whole width of
the slab. The equipment for striking-off the concrete
shall be capable of being rapidly adjusted for
changes of the average and differential surcharge
necessitated by
Page 617 of 1427

change in slab thickness or crossfail.
602.9.6.2. The level of the conforming plate

and finishing beams shall be controlled
automatically from the guide wires installed as per
Clause 602.8 by sensors attached at the four corners
of the slip form paving machine. The alignment of
the paver shall be controlled automatically from the
guide wire by at least one set of sensors attached to
the paver. The alignment and level of ancillary
machines for finishing, texturing and curing of the
concrete shall be automatically controlled relative to
the guide wire or to the surface and edge of the slab.
602.9.6.3. Slip-form paving machines shall

have vibrators of variable output, with a maximum
energy output of not less than 2.5 KW per metre
width of slab per 300 mm depth of slab for a laying
speed upto 1.5 m per minute or pro-rata for higher
speeds. The machines shall be of sufficient mass to
provide adequate reaction during spreading and
paving operations on the traction units to maintain
forward movements during the placing of concrete
in all situations.
602.9.6.4. If the edges of the slip formed slab

slump to the extent that the surface of the lop edge of
the slab does not comply with the requirements of
Clause 602.14, then special measures approved by
the Engineer shall be taken to support the edges to
the required levels and work shall be stopped until
such time as the Contractor can demonstrate his
Page 618 of 1427

ability to slip form the edges .to the required levels.
602.9.7. Construction by hand-guided

method: Areas in which hand-guided methods of
construction become indispensable shall be got
approved by the Engineer in writing in advance.
Such work may be permitted only in restricted areas
in small lengths. Work shall be earned cut by skilled
personnel as per methods approved by the Engineer.
The acceptance criteria regarding level, thickness,
surface regularity, texture, finish, strength of
concrete and all other quality control measures shall
be the same as in the case of machine laid work.
602.9.8. Surface texture
602.9.8.1. After the final regulation of the

slab and before the application of the curing
membrane, the surface of concrete slab shall be
brush-textured in a direction at right angles to the
longitudinal axis of the carriageway.
602.9.8.2. The brushed surface texture shall

be applied evenly across the slab in one direction
by the use of a wire brush not less than 450 mm wide
but longer brushes are preferred. The brush shall be
made of 32 gauge tape wires grouped together in
tufts spaced at 10 mm centres. The tufts shall contain
an average of 14 wires and initially be 100 mm
long. The brush shall have two rows of tufts. The
rows shall be 20 mm apart and the tufts in one row
shall be opposite the centre of the gap between tufts
Page 619 of 1427

in the other row. The brush shall be replaced when
the shortest tuft wears down to 90 mm long.
602.9.8.3. The texture depth shall be

determined by the Sand Patch Test as described in
Clause 602.12. This test shall be performed at least
once for each day’s paving and wherever the
Engineer considers it necessary at times after
construction as under:
Page 620 of 1427

Five individual measurements of the texture
depth shall be taken at least 2 m apart anywhere
along a diagonal line across a lane width between
points 50 m apart along the pavement No
measurement shall be taken within 300 mm of the
longitudinal edges of a concrete slab constructed in
one pass.
602.9.8.4. Texture depths shall not be less

than the minimum required when measurements are
taken as given in Table 600-2 nor greater than a
maximum average of 1.25 mm.
TABLE : 600-2. Texture Depth
Number of
Time of Test Measurements Tex
Specified
1. Between 24 hours and 7 days An average of 1.00
after the constn., of the slab or 5 measurements
until the stab is first used by
vehicles.
2. Not later than 6 weeks before the An average of 1.00
road is opened 10 public traffic. 5 measurements
602.9.8.5. After the application of the

brushed texture, the surface of the slab shall have a
uniform appearance
602.9.8.6. Where the texture depth

requirements are found to be deficient, the
Contractor shall make good the texture across the
Page 621 of 1427

full lane width over length directed by the Engineer,
by retexturing the hardened concrete surface in an
approved manner.
602.9.9. Curing
602.9.9.1. Immediately after the surface

texturing, the surface and sides of the slab shall be
cured by the application of approved resin- based
aluminised reflective curing compound which
hardens into an impervious film or membrane with
the help of a mechanical sprayer.
Curing compounds shall contain sufficient
flake aluminium in finely divided dispersion to
produce a complete coverage of the sprayed surface
with a metallic finish. The compound shall become
stable and impervious to evaporation of water from
the surface of the concrete within 60 minutes of
application and shall be of approved type. The
curing compounds shall have a water retention
efficiency index of 90 per cent in ac-cordance with
BS Specification No. 7542.
602.9.9.2. The curing compound shall not

react chemically with the concrete and the film or
membrane shall not crack, peel or disintegrate within
three weeks after application. Immediately prior to
use, the curing compound shall be thoroughly
agitated in its containers. The rate of spread shall be
in accordance with the manufacturer’s instructions
checked during the construction of the trial length
and subsequently whenever required by the
Page 622 of 1427

Engineer. The mechanical sprayer shall incorporate
an efficient mechanical device for continuous
agitation and mixing of the compound during
spraying.
Page 623 of 1427

602.9.9.3. In addition to spraying of curing
compound, the fresh concrete surface shall be
protected for at least 3 hours by covering the
finished concrete pavement with tents as described
in Clause 602.7.2, during adverse weather conditions
as directed by the Engineer. After three hours, the
pavement shall be covered by moist hessian and the
same shall then be kept damp for a minimum period
of 14 days after which time the hessian may be
removed. The hessian shall be kept continuously
moist. All damaged/torn hessian shall be removed
and replaced by new hessian on a regular basis.
602.9.9.4. The Contractor shall be liable at

his expense to replace any concrete damaged as a
result of incomplete curing or cracked on a it line
other than that of a joint.
602.10. Trial Length
602.10.1. The trial length shall be

constructed at least one month in advance of the
proposed start of concrete paving work. At least one
month prior to the construction of the trial length, the
Contractor shall submit for the Engineer’s approval a
detailed method statement giving description of the
proposed materials, plant, equipment and
construction methods. All the major equipments like
paving train, batching plant, tippers etc., proposed in
the construction are to be approved by the Engineer
before their procurement. No trials of new materials,
plant, equipment or construction methods, nor any
Page 624 of 1427

development Of them shall permitted either during
the construction of trial length or in any subsequent
paving work, unless they form part of further,
approved trials. These trial lengths shall be
constructed away from the carriage-but with at least
a subbase layer below it.
602.10.2. The Contractor shall demonstrate

the materials, plant, equipment and methods of
construction that are proposed for concrete paving,
by first constructing a trial length of slab, at least 60
m but not more than 300 m long for mechanised
construction and at least 30 m long for hand guided
methods. If the first trial is unsatisfactory, the
Contractor shall have to demonstrate his capability
to satisfactorily construct the pavement in
subsequent trials.
602.10.3. The trial length shall be

constructed in two parts over a period comprising at
least part of two separate working days, with a
minimum of 30 m constructed each day for
mechanised construction and minimum of 15 m on
each day for hand guided construction. The trial
length shall be constructed at a similar rate (speed,
around lm/hr) to that which is proposed for the main
work.
602.10.4. Transverse joints and longitudinal

joints of each type that are proposed for dowel-
jointed unreinforced concrete slabs in the main work
shall be constructed and assessed in the trial length.
Page 625 of 1427

If in the trial length the construction of expansion
joint and longitudinal joint is not remonstrated, the
first 2 expansion joints and at least the first 150m of
longitudinal construction joint for mechanised
paving in the main work, shall be considered as the
trial length for these joints.
602.10.5. The trial length shall comply with

the Specification in all respects, with the following
additions and exceptions:
Page 626 of 1427

602.10.5.1. Surface levels and regularity
(i) In checking for compliance with

Clause 903.5 the levels shall he taken
at intervals at the locations specified
in this Clause along any line or lines
parallel to the longitudinal centre line
of the trial length.
(ii) The maximum number of permitted
irregularities of pavement surface
shall comply with the requirements of
Clause 902.4. Shorter trial lengths
shall be assessed prorata based on
values for a 300 m length.
602.10.5.2. Joints
(iii) Alignment of dowel bars shall be
inspected as described in Clause
602.10.7 in any two consecutive
transverse joints. If the position or
alignment of the dowel bars at one of
these joints does not comply with
Clause 602.6.5, if that joint remains
the only one that does not comply
after the next 3 consecutive joints of
the same type have been inspected,
then the method of placing dowels
shall be deemed to be satisfactory. In
order to check sufficient joints for
dowel bar alignment without
extending the trial length unduly, the
Contractor may, by agreement with
Page 627 of 1427

the Engineer, construct joints at more
frequent joint intervals than the
normal spacing required in the
Contract.
(iv) If there are deficiencies in the first
expansion joint that is constructed as
a trial, the next expansion joint shall
be a trial joint Should this also be
deficient, further trial expansion
joints shall be made as part of the trial
length which shall not form pan of the
permanent works, unless agreed by
the Engineer.
602.10.5.3. Density
(v) Density shall be assessed as

described in Clause drilled from each
pan of the trial length.
602.10.5.4. Position of tie bars

(vi) Compliance with Clause 602.6.6 for
the position and alignment of tie bars
shall be checked by drilling additional
cores from the slab unless they can be
determined from cores taken for
density.
602.10.6. Approval and acceptance
602.10.6.1 Approval of the materials, plant,

equipment and construction methods shall be given
Page 628 of 1427

when a trial length complies with the Specification.
The Contractor shall not proceed with normal
working until the trial length has been approved and
any earlier defective trial lengths have been
removed, unless that can be remedied to the satisfac-
tion of the Engineer. If the Engineer does not notify
the Contractor of any deficiencies in any trial length
within 10 days after the completion of that trial
length, the Contractor may assume that the trial
length, and the materials, plant, equipment and
construction methods adopted are acceptable.
602.10.6.2. When approval has been given,

the materials, plant, equipment and construction
methods shall not thereafter be changed, except for
normal adjustments and maintenance of plant,
without the approval of the Engineer. Any changes
in materials,
Page 629 of 1427

plant, equipment, and construction methods shall
entitle the Engineer to require the Contractor to lay a
further trial length as described in this Clause to
demonstrate that the changes will not adversely
affect the permanent works.
602.10.6.3. Trial lengths which do not

comply with the Specification, with the exception of
areas which are deficient only in surface texture and
which can be remedied in accordance with Clause
602.9.8.6 shall be removed immediately upon
notification of deficiencies by the Engineer and the
Contractor shall construct a further trial length.
602.10.7. Inspection of dowel bars
602.10.7.1. Compliance with Clause 602.6.5.

for the position and alignment of dowel bars at
construction and expansion joints shall be checked
by measurements relative to the side forms or guide
wires.
602.10.7.2. When the slab has been

constructed, the position and alignment of dowel
bars and any filler board shall be measured after
carefully exposing them in the plastic concrete
across the whole width of the slab. When the joint is
an expansion joint, the top of the filler board shall
first be exposed sufficiently in the plastic concrete to
permit measurement of any lateral or vertical
displacement of the board. During the course of
normal working, these measurements shall be carried
Page 630 of 1427

out the pavement section at the end of day’s work by
extending slab length 2m. After sawing the
transverse joint groove, the extended 2 m slab shall
be removed carefully soon after concrete has set to
expose over half the length. These dowels can be
tested for tolerances.
602.10.7.3. If the position and alignment of

the bars in a single cement in the slab is
unsatisfactory then the next two joints shall be
respected. If only one joint of the three is defective,
the rate of checking shall be increased to one joint
per day until the Engineer is satisfied that
compliance is being achieved. In the event of non-
compliance in two more successive joints, the
Contractor shall revert to the construction fresh trial
lengths and make any necessary alteration to
concrete mix, paving plant or methods until the
dowel bar position and alignment satisfactory.
602.10.7.4. After the dowel bars have been

examined, the remainder the concrete shall be
removed over a width of 500 mm on each side the
line of the joint and reinstated to the satisfaction of
the Engineer, the dowels shall be inserted on both
sides of the 1 m wide slab by drilling holes and
grouting with epoxy mortar. Plastic sheath as per
Clause 602.5.5. shall be provided on dowels on one
of the joints. The joint above shall be widened and
sealed as per Clause 602.11.
602.11. Preparation and Sealing of Joint
Page 631 of 1427

Grooves
602.11.1. General
All transverse joints in surface slabs shall be

sealed using sealants described in Clause 602.2.8.
Joints shall not be sealed before -14 days after
construction.
602.11.2. Preparation of joint grooves for

sealing
Page 632 of 1427

602.11.2.1. Joint grooves usually are not
constructed to provide the minimum width specified
in the drawings when saw cut joints are adopted.
They shall be widened subsequently by sawing
before sealing, depth/width gauges shall be used to
control the dimension of the groove.
602.11.2.2. If rough arrises develop when

grooves are made, they shall be ground to provide a
chamfer approximately 5 mm wide. If the groove is
at an angle upto 10 degree from the perpendicular to
the surface, the overhanging edge of the sealing
groove shall be sawn or ground perpendicular. If
spalling occurs or the angle of the former is greater
than 10 degrees, the joint sealing groove shall be
sawn wider and perpendicular to the surface to
encompass the defects upto a maximum width,
including any chamfer, of 35 mm for transverse
joints and 20 mm for longitudinal joints. If the
spalling cannot be so eliminated then the arrises shall
be repaired by an approved thin bonded arris repair
using cementitious materials.
602.11.2.3. All grooves shall be cleaned of

any dirt or loose material by air blasting with
filtered, oil-free compressed air. If need-arises the
Engineer may instruct cleaning by pressurised water
jets. Depending upon the requirement of the sealant
manufacturer, the sides of the grooves may have to
be sand blasted to increase the bondage between
sealant and concrete.
Page 633 of 1427

602.11.2.4. The groove shall be cleaned and
dried at the Lime of priming and sealing.
602.11.2.5. Before sealing the temporary seal

provided for blocking the ingress of dirt, soil etc.,
shall be removed. A highly compressible heat
resistant paper-backed debonding strip as per
drawing shall be inserted in the groove to serve
the purpose of breaking the bond between sealant
and the bottom of the groove and to plug the joint
groove so that the sealant may not leak through the
cracks. The width of debonding strip shall be more
than the joint groove width so that it is held tightly in
the groove. In the case of longitudinal joints, heat
resistant tapes may be inserted to block the leakage
through bottom of the joint.
602.11.3. Sealing with sealants
602.11.3.1. When sealants are applied, an

appropriate primer shall also be used if
recommended by the manufacturer and it shall be
applied in accordance with their recommendation.
The sealant shall be applied within the minimum
and maximum drying times of the primer
recommended by the manufacturer. Priming and
sealing with applied sealants shall not be carried out
when the naturally occurring temperature in the joint
groove to be sealed is below 7° C.
602.11.3.2. If hot applied sealant is used it

shall be heated and applied from a thermostatically
Page 634 of 1427

controlled, indirectly heated preferably with oil
jacketed melter and pourer having recirculating
pump and extruder. For large road projects, sealant
shall be applied with extruder having flexible hose
and nozzle. The sealant shall not be heated to a
temperature higher than the safe heating temperature
and not for a period longer than the safe heating
period, as specified by the manufacturer. The
dispenser shall be cleaned out at the end of each day
in accordance with the manufacturer’s
recommendations and reheated material shall not be
used.
Page 635 of 1427

602.11.3.3. Cold applied sealants with
chemical formulation like polysulphide may be used.
These shall be mixed and applied within the time
limit specified by the manufacturer. If primers are
recommended they shall be applied neatly with an
appropriate brush. The Movement Accommodation
Factor (MAP) shall be more than 10 per cent.
602.11.3.4. The sealants applied at

contraction phase of the slabs would result in
bulging of the sealant over and above the slab.
Therefore, the Contractor in consultation with the
Engineer, shall establish the right temperature and
time for applying the sealant. Thermometer shall be
hung on a pole in the site for facilitating control
during the sealing operation.
602.11.3.5. Sealant shall be applied, slightly

to a lower level than the slab with a tolerance of 5 ±
2 mm.
602.11.3.6. During sealing operation, it shall

be seen that no air bubbles are introduced in the
sealant either by vapours or by the scaling process.
602.11.4. Testing of applied sealants:

Manufacturer’s certificate shall be produced by the
Contractor for establishing that the sealant is not
more than six months old and stating that the sealant
complies with the relevant standard as in Clause
602.2.8. The samples shall meet the requirement of
AASHTO M 282 for hot applied sealant or BS 5212:
Page 636 of 1427

(Pan-2) for cold applied sealant.
602.12. Measurement of Texture Depth -

Sand Patch Method
602.12.1. The following apparatus shall be

used:
(i) A cylindrical container of 25 ml
internal capacity
(ii) A flat wooden disc 64 mm diameter
with a hard rubber disc, 1.5mm thick,
stuck to one face, the reverse face
being provided with a handle
(iii) Dry natural sand with a rounded
panicle shape passing a 300 micron IS
sieve and retained on a 150 micron IS
sieve.
602.12.2. Method: The surface to be

measured shall be dried, any extraneous mortar and
loose material removed and the surface swept clean
using a wire brush both at right angles and parallel
to the carriageway. The cylindrical container shall be
filled with the sand, tapping the base 3 times on
the surface to ensure compaction, and striking off
the sand level with the top of the cylinder. The sand
shall be poured into a heap on the surface to be
treated. The sand shall be spread over the surface,
working the disc with its face kept flat in a circular
motion so that the sand is spread into a circular patch
with the surface depressions filled with sand to the
level of peaks.
Page 637 of 1427

602.12.3. The diameter of the patch shall be
measured to the nearest 5 mm. The texture depth of
concrete surface shall be calculated from
31000/(DxD) mm where D is the diameter of the
patch in mm.
No vehicular traffic shall be allowed to run

on the finished surface of a concrete pavement
within a period of 28 days of its construction and
until the joints are
Page 638 of 1427

permanently sealed. The road may be opened to
regular traffic after completion of the curing period
of 28 days and after sealing of joints is completed
including the construction of shoulder, with the
written permission of the Engineer.
602.14. Tolerances for Surface Regularity,

Level, Thickness and Strength

thickness and strength /shall conform to the
requirements given in Clause 903.5. Control of
the Engineer in -accordance with Section 900
602.15.1. Cement Concrete pavement shall

be measured as a finished work in square metres
with specified thickness. The volume to be paid for
will be calculated on the basis of thickness and plans
shown on project drawings and adjusted for the
deficiency in thickness. No additional payment
shall be made for extra thickness of the slab. The full
payment will be made to this item after 28 days
strength of the concrete is found to be satisfactory.
The unit for measurement for concrete
pavement shall be the cubic of concrete placed,
based on the net plan areas for the specified
thickness shown on the Drawings or directed by the
Engineer. The rate shall include all provisions of this
Specification and shall include the vision of all
Page 639 of 1427

materials including polythene film, concrete, stock
piling, transport, placing, compacting, finishing,
curing together with all formwork, and including
testing and submission of test certificates and No
deduction shall be made in measurement for
openings provided that the area of each is less
than 0.5 sq. m. The unit rate as entered in the Bill
of Quantities shall also include the full costs of
contraction, expansion, construction, and
longitudinal joints. It shall also include joint filler,
keys, caulking rod, deboriding strip, sealant primer,
joint sealant, dowel bar and tie rod.
602.15.2. Pavement thickness
All precautions and care shall be taken to

construct pavement having uniform thickness as
called for on the plans.
Thickness of the cement concrete pavement
shall be calculated on the basis of level data of the
cement concrete pavement and the underlying sub-
base taken on a grid of 5 m x 3.5 m or 6.25 m x 3.5
m, the former measurement being in longitudinal
direction.
A day’s work is considered as a ‘lot’ for
calculating the average thickness of the slab. In
calculating the average thickness, individual
measurements which are in excess of the specified
thickness by more than 10 mm shall be considered as
the specified thickness plus 10 mm.
Individual areas deficient by more than 25
mm shall be verified by the Engineer by ordering
Page 640 of 1427

core cutting and if in his opinion the deficient areas
warrant removal, they shall be removed and replaced
with concrete of the thickness shown on the plans.
When the average thickness for the lot is
deficient by the extent shown in Table 600-3, the
Contract unit price will be adjusted as per this Table.
Page 641 of 1427

TABLE 600-3. PAYMENT ADJUSTMENT FOR
DEFICIENCY IN THICKNESS
Deficiency in the Per cent of Contract

average unit price payable
thickness of day’s work
Up to 5 mm 100
6-10 mm 87
11 - 15 mm 81
16 - 20 mm 75
21 - 25 mm 70
In the stretch where deficiency of average

thickness is more than 25 mm, the section whose
thickness is deficient by 26 mm or more is identified
with the help of cores. Such slabs shall be removed
and reconstructed at the cost of the Contractor.
During such rectification work, care shall be taken to
replace full slab and to the full depth.
602.16. Rate
The Contract unit rate for the construction of

the cement concrete shall be payment in full for
carrying out the operations required for the different
items of the work as per these Specifications
including full compensation for all labour, tools,
Page 642 of 1427

plant, equipments, testing and incidentals to
complete the work as per Specifications, providing
all materials to be incorporated in the work including
all royalties, fees, storage, rents where necessary and
all leads and lifts.
603. ROLLED CEMENT CONCRETE BASE
603.1. Scope

construction of rolled concrete base course for
cement concrete pavement in accordance with the
requirements of these Specifications and in
conformity with the lines, grades and cross sections
shown on the drawings or as directed by the
Engineer. The work shall include furnishing of all
plant and equipment, material and labour and
performing all operations in connection with the
work, as approved by the Engineer.
603.1.2. The design parameters of rolled

cement concrete base course viz., width, thickness,
grade of concrete, details of joints, if any, etc. shall
be as stipulated in the contract drawings.
603.2. Materials
603.2.1. Source of materials: The

of all materials to be used in the lean concrete work
with relevant test data sufficiently in advance and the
Page 643 of 1427

approval of the Engineer for the same shall be
obtained at least 60 days before the tiled
proposes obtain the materials from a different
source, he shall notify the peer for his approval at
Page 644 of 1427

least 60 days before such materials are to be used.
603.2.2. Cement: Any of the following types

of cement may be used prior approval of the
Engineer.
(i) Ordinary Portland Cement
IS : 269, 8112 or 12269
(ii) Portland Slag Cement
IS : 455
(iii) Portland Pozzolana Cement
IS : 1489
If the subgrade is found to consist of
soluble sulphates in a concentration more than 0.5
per cent, cement used shall be sulphate resistant and
shall conform to IS: 12230. Cement to be used may
preferably be obtained in bulk form. It shall be
stored in accordance with stipulations contained in
Clause 1014 and shall be subjected to acceptance test
prior to its immediate use.
603.23. Aggregates :
603.2.3.1. Aggregates for lean concrete shall

be natural material complying with IS: 383. The
aggregates shall not be alkali reactive. The limits of
deleterious materials shall not exceed the
requirements set out in IS: 383. In case the Engineer
considers that the aggregates are not free from din,
hours before batching as directed by the Engineer.
603.2.3.2. Coarse aggregate : Coarse
Page 645 of 1427

aggregates shall consist of clean, hard, strong, dense,
angular or splintery pieces. The maximum size of the
coarse aggregate shall be 25 mm. The coarse
aggregate shall comply with the Clause 602.2.4.2.
603.2.3.3. Fine aggregate : The fine

aggregate shall consist of clean natural sand or
shall conform to IS:383. Fine aggregate shall be
particles, mica, organic and other foreign matter. The
fine aggregate shall comply with the Clause
602.2.4.3.
603.2.3.4. The coarse and fine aggregates

may be obtained in cither of the following manner:-
(i) In separate nominal sizes of coarse
and fine aggregates and mixed
together intimately before use.
(ii) Separately as 25 mm nominal single
size, 12.5 mm nominal size graded
aggregate and fine aggregate of
crushed stone dust or sand or a
combination of these two.
The material after blending shall conform to

the grading as indicated in Table 600-4 below:
Page 646 of 1427

FOR DRY LEAN CONCRETE
Sieve Designation Percentage P

sieve by
37.5 mm 10
19.0 mm 80-1
9.5 mm 55-
4.75 mm 35-
600 micron 10-
75 micron 0-

injurious amount of oil, salt, acid, vegetable matter
It shall meet the requirements stipulated in IS: 456.

Clause 1014 of these Specifications, and other
relevant IS Specifications. All efforts must be made
to store the materials in proper places so as to
prevent their Deterioration or contamination by
and fitness for the work. The storage place must also
permit easy inspection, removal and storage of
materials. All such materials even though stored in
approved godowns must be subjected to acceptance
test immediately prior to their use. The requirement
of storage yard specified in Clause 602.2.9 shall be
applicable.
Page 647 of 1427

603.3. Proportioning of Materials for the
Mix
603.3.1. The mix shall be proportioned with a

maximum aggregate: cement ratio of 15:1. After the
approval of all the materials to be used in the
concrete, the Contractor shall submit the mix design
based on weighed proportion of all ingredients for
the approval of the Engineer. The mix design shall
be submitted at least 30 days prior to the paving of
trial length and design shall be done based on the
laboratory trials using approved materials and
methods. The water content shall be adjusted to the
optimum as per Clause 603.3.2. for facilitating
compaction by rolling. The target mean strength for
the design mix as well as acceptance Specification of
concrete shall be in accordance with Clause 903.5.2.
The mix design shall be based on the flexural
strength of concrete.
603.3.2. Moisture content: The right amount

of water for the rolled concrete in the main work
shall be decided for ensuring full compaction under
rolling and shall be assessed at the time of rolling the
trial length. Too much water will cause the concrete
to be picked up on the wheels of the roller and too
little will lead to inadequate compaction, a low in-
situ strength and an open textured surface. The
optimum water content shall be determined in
accordance with Clause 603.7. and, demonstrated by
rolling during trial length construction and the
Page 648 of 1427

optimum moisture content and degree of compaction
shall be got approved by the Engineer. While
laying, in the main work, the rolled concrete shall
have a moisture content between the optimum and
optimum + 2 per cent, keeping in view the
effectiveness of compaction achieved and to
compensate for evaporation losses.
603.3.3. Cement content: The minimum

cement content in the rolled concrete shall not be
less than 150 kg/cu.m. of concrete. If this minimum
cement content is not
Page 649 of 1427

sufficient to produce concrete of the specified
strength, it shall be increased as necessary without
additional compensation under the Contract.
603.3.4. Concrete strength: The flexural

strength as specified shall be the governing criteria
for approval of the mix. While designing the mix in
the laboratory, correlation between flexural and
compressive strengths of concrete shall be
established on the basis of tests on samples for use at
a later date to verify the in situ flexural strength of
rolled concrete through testing of cores.
At least a batch of two beam and cube
specimens, one each for 3 day and 7 day strength
testing shall be cast for every 100 cum or pan thereof
of concrete placed during construction. On each
day’s work not less than four beams and four cubes
shall be made.
A ratio between the 3 and 7 day strengths
shall be established for the mix to be used. This will
help in assessing the fall in strength, if any in
advance so that corrective action can be taken for the
future work.
603.4. Subgrade
The subgrade shall conform to the grades and

cross sections shown on the drawings and shall be
uniformly compacted to the design strength in
accordance with these Specifications and the
Specification stipulated in the Contract. The rolled
concrete base shall not be laid on a subgrade
Page 650 of 1427

softened by rain after its final preparation; any
surface trenches, soft spots etc., must be properly
back-filled and compacted to avoid any weak or soft
spot. As far as possible, the construction traffic shall
be avoided on the prepared subgrade. A day before
placing of die sub-base, the subgrade surface shall be
given a fine spray of water and rolled with one or
two passes of a smooth wheeled roller after a lapse
of 2-3 hours in order to stabilise the loose surface. If
the Engineer feels it necessary, another fine spray of
water may be applied just before placing the base
course.
603.5. Construction
Clause 601.5 shall apply.
603.6. Trial Mix
Using the specified cement content and

proportioned aggregates, the Contractor shall make
trial mixes at water contents ranging from 5 per cent
to 7 per cent by weight of dry materials at 0.5
percent intervals using an aggregate cement ratio of
not greater than 15.0. Optimum moisture and density
shall be established by preparing cubes with varying
Moisture contents. The compaction of mould shall
be done in three layers as explained in Clause
903.5.2.1. The optimum moisture content deter-
mined normally gives an indication about the
moisture content which after minor adjustment may
provide satisfactory mix which could be rolled.
Page 651 of 1427

After determining the moisture content from
the above trial mix, a set of six beams and cubes
shall be prepared for testing them on 3rd and 7th
day. If the flexural strength achieved is lower than
the desired strength, the above trial shall be repeated
after increasing the cement content and adjusting the
mix appropriately.
During the construction of trial length as per
Clause 603.7 minor modifications may have to be
carried out to the moisture content of the mix. But
such modified mix shall have to satisfy the flexural
strength requirement. Flexural strength to be
achieved shall be the governing criteria for the
design of mix.
Page 652 of 1427

603.7. Trial Length
Clause 601.7 shall apply.
603.8. Traffic
No heavy commercial vehicles like trucks

and buses shall be permitted on the rolled concrete
base after its construction. Light vehicles may be,
however, allowed after 7 days of its construction
with prior approval of the Engineer.
603.9. Tolerances for Surface Regularity,

Level, Thickness and Strength

thickness and strength shall conform to the
requirements given in Clause 903.S. Control of
the Engineer in accordance with Section 900.
The unit of measurement for concrete and

rolled concrete pavement shall be the cubic metre of
concrete placed, based on the net plan areas for the
specified thickness shown on the drawings as
603.11. Rate
The Contract unit rate payable for rolled
Page 653 of 1427

cement concrete for base course shall be payment in
including full compensation for all labour, materials
and equipment, mixing, transport, placing,
compacting, finishing, curing, testing and ,
incidentals to complete the work as per
Specifications, all royalties, fees, storage and rents
where necessary and all leads and lifts.
Page 654 of 1427

Geosynthetics
700
Geosynthetics
Page 655 of 1427

701. GEOSYNTHETICS IN ROAD AND
BRIDGE WORKS
701.1 Scope
This specification covers the various

applications of Geosynthetic materials in road and
bridge works including supplying and laying as per
special provisions.
“Geosynthetic is a general classification for
all synthetic materials used in geotechnical
engineering application. It includes geotextiles,
geogrids, geonets, geomembranes and
geocomposites.
(i) Ceotextile : Any permeable textile
natural or Synthetic, used with
foundation, soil, rock, earth, or any
other geotechnical engineering related
material. In the present chapter, it is
related to synthetic material only.
(ii) Geogrid : A deformed or non-
deformed grid of polymeric material
used primarily for reinforcement
purposes with foundation, soil, rock,
earth, or any other geotechnical
engineering related material.
(iii) Geonets : These are net made of
polymeric material used for drainage
of foundation, soil, rock, earth or any
other geotechnical engineering related
material.
(iv) Geomembrane : An essentially
Page 656 of 1427

impermeable membrane of polymeric
material used with foundation, soil,
rock, earth or any other geotechnical
engineering related material, to
control fluid migration.-
(v) Geocomposite : A manufactured
material using geottxtiles. geogrids,
geonets and/ or geomembrane in
laminated or composite form.”
701.2 Material Testing and Acceptance
Unless otherwise stated, these Geosynthetic

materials shall conform to the requirements as under
:
701.2.1. Geotextile : Geotextile shall be

made of polyethylene or polypropylene or polyester
or similar fibres, either woven or nonwoven in
variety, through machine made process of
heatbonding or needle punching or weaving
techniques. These fabrics are required to pass water
through but retain the soil particles, which require
specific cross-plane permeability or permittivity and
apparant opening size or equivalent opening size or
095. The above two requirements alongwith the
requirement of strength and durability denote general
characteristics of geotextiles to be used.
The type of geotextile to be used in a
particular application shall be decided on the basis of
design.
Page 657 of 1427

701.2.2. Geogrid : Geogrid shall be made
from integrally jointed, mono or bi-directionally
orientated or stretched meshes made from
polyethylene or polypropylene or polyester or
similar polymer, with high modulus, in square,
rectangular, hexagonal or oval mesh farm. Their
junction strength shall be high with high creep
resistance, and dimensional stability. Their open
structure shall permit effective interlocking with soil,
aggregates, rock etc., they shall be used as a tensile
member are reinforcement. Characteristics strength
of such Geogrids varies from 40 kN/m to 200 kN/m
peak strength at a maximum elongation of 15 per
cent of the direction of the length of the roll.
701.2.3. Geonet: Geonet shall be made from

a single extruded oriented process from polyethylene
or polypropylene or similar polymer. It shall have
square or
Page 658 of 1427

rectangular net shape aperture when used for
protective works like gabions and mattresses. While
in polygonal aperture it shall be used as a separator.
It shall not be used as soil reinforcement due to its
high creep characteristics, neither as a slope
reinforcement or soil retaining wall or asphaltic
reinforcement. Geonets used in protective works for
highway structures shall be atleast 650 gm/ fen. in
unit weight. It shall be black in colour, available in
roll form in suitable width.
701.2.4. Geomembrane : Geomembrane

shall be made from PVC or polyethylene sheets of
atleast 0.8 mm thickness, duly protected from
ultraviolet exposure with 2.5 per cent carbon black,
in black colour, supplied roll form with 3 m or
above width. The joints of these sheets shall be eat
bonded or seamed for effective permeation cut off, at
site using standard equipment as pan of the laying
process. While fixing on to a lope, they shall not be
punctured or stappled to impair their use.
701.2.5. Geocomposite : Geocompositcs

shall be made from combination of geonets, geogrids
or geomembranes of above description using eat
bonded, seamed stitched or wrap techniques. Their
principal use shall be to regulate drainage in cross-
plane or in-plane directions. Minimum weight of
such material shall conform to the special provisions
or as Contract drawing.
761.2.6. Testing and acceptance :
Page 659 of 1427

Geosynthetics shall be tested in accordance with
tests prescribed by BIS. In absence of IS Codes, tests
prescribed either by ASTM or British Standards or
International Standards Organization, shall be
conducted.
701.3 Application Areas
Some of the application areas for geotextiias

and related materials and functions are given below
in table 700-1.
Table 700-1. Applications and Functions of

Geosynthetics
S.NO. Application Area Geosynthetics

Involved
1. Embankments on soft soils GT, GG

2. Retaining walls GG, GT
3. Drainage and Filtration GT
4. Drainage-prefab, composite GC, GN
5. Erosion Control rip rap GT
6. Sediment control-silt fence GT
7. Asphalt overlay GT, GC
Note : GT = geotextile S = separation
GG = geogrid R = reinforcement
GC = geocomposite F = filtration
GN = geonet D = drainage
B = barrier
Page 660 of 1427

702. GEOTEXTILES IN SUB-SURFACE
DRAINS
702.1. Scope
The work covers the use of geotextiles in

subsurface drains, such as fin drains or narrow, filter
drains. The fin drain shall mean a planar
geocomposite structure designed to perform the
same function as a narrow liter drain. The work shall
be carried out as per design drawings.
702.2. Materials
702.2.1. The geotextile fabric shall be a

woven or non-woven fabric consisting of long-chain
polymeric filaments or yarns such as polypropylene,
polyethylene or polyester or any combination
thereof, formed into a stable network such that the
filaments or yams retain their relative position to
each other.
702.2.2. The geosynthetic material of which

the drain is made shall be treated with carbon black
so that they are protected from the deleterious effects
of short term exposure to ultraviolet light, and shall
be resistant to ion by acid, alkalis, common
chemicals, bacteria, fungi and moulds occurring in
soils and highway construction materials. In case of
sure to ultraviolet light, the Engineer may require
evidence that the synthetic material still complies
with the requirements of this Clause. Where
Page 661 of 1427

necessary, the side intended for entry of water and
direction of in-plane flow shall be identified.
702.2.3. The geotextile shall :
(a) Sustain a load of not less than 10

kN/m at break and have a minimum
failure strain of 10 per cent when
determined in accordance with
BS:6906 (Part I) or stall have grab
tensile strength more than 0.4 kN/m
and grab elongation corresponding to
this limit in accordance with ASTM
D 4632.
(b) The apparent opening size*” shall
satisfy the following.
Test Units Requirements

Method
per cent in-situ soil passing
0.075 mm
>15 15 to >50
50
ASTM
mm 0.43 0.25 0.22**
D4751
* These default filtration property

values are based on the predominant
panicle size of in-situ soil. In addition
to the default permittivity value, the
Engineer may require geotextile
permeability and/or performance
Page 662 of 1427

testing based on engineering design
for drainage systems in problematic
soil environments.
@ Site specific geotextile design
should be performed especially if one
or more of the following problematic
soil environments are encountered;
unstable or highly credible soils such
as non-cohesive silts; gap graded
soils; alternating sand/sill laminated
coils; dispersive clays; and/or rock
flour.
** For cohesive soils with a plasticity

index greater than 7, geotextile
maximum average roll values for
apparent opening size is 0.30 mm.
(c) allow water to flow through it at right
angles to its principal plane, in either
direction at a rate of not less than 10
litres/m2/sec. under a constant head of
water of 100 mm. determined in
accordance with BS:6906 (Part 3) or
ASTM D 4491 or as stated in the
design drawing. The flow rate
determined in the test shall be
corrected to that applicable to a
temperature of 15°C using published
data on variation in viscosity of water
with temperature
(d) have a minimum puncture resistance
of 200 N when determined in
Page 663 of 1427

accordance with BS.-6906 (Part 4) or
ASTM D 4833.
(c) have a minimum tear resistance of
150 N when determined in
accordance with ASTM Standard D
4533.
702.2.4. The composite drain shall have a

flow rate through each face of the drain of more than
75 per cent of the value specified in sub-Clause
702.2.3 (c), determined by direct measurement of the
composite drain using BS:6906 (Part 3). The
composite drain shall have values of long-term in-
plane flow rates as stated in the design drawing.
702.3. Installation
702.3.1. The installation of fin drains shall be

as per the design drawings. Where fin drains are
assembled on site, the assembly area shall be clean
and dry and free of any wind-borne pollutants. No
geotextile or core material shall be exposed to
daylight (or any source of ultraviolet radiation) for a
period exceeding a cumulative total of 50 hours.
Where fin drains are laid in trench, the bottom of the
trench shall be free of irregularities and shall be
brought to the required level. Rock and other hard
protrusions shall be removed and any excess cut in
the trench bottom filled and compacted back to the
required grade with suitable excavated or imported
material as directed by the Engineer. Fin drains shall
be capable of being jointed longitudinally or laterally
Page 664 of 1427

into pipe systems or chambers for inflow and
outflow purposes. Joints parallel to the direction of
flow and any exposed edged shall be protected from
the ingress of soil by a geotextile wrapping with a
minimum overlap of 150 mm or other measures as
agreed by the Engineer.
702.4. Narrow filter drains consisting of a

porous or perforated pipe laid in a narrow trench
surrounded by a layer of geotextile filter shall have
the same properties of geotextile as specified in
Clause 702.2. The spicing of lengths of geotextile
and minimum overlap shall be as per the design
drawing or as approved by the Engineer. Such drains
shall be installed as per the design drawing to
Clauses 702.3 and 309.3.5.
Measurement for fin drain/narrow filter

drains shall be per running metre length of the drain.
Disposal of surplus material beyond 1000 m shall be
measured in cu.m.
702.6. Rates
The Contract unit rates for subsurface drains

shall be payment in full for all items such as
excavation, dressing the sides and bottom, providing
geotextile composites,
Page 665 of 1427

laying and jointing pipes etc. including full
compensation for all materials, labour, tools,
equipment incidental to complete the work as shown
on drawings with all leads and lifts except for
removal of unsuitable material for which the lead
shall be 1000 m. Provision of inlets, outlet pipes,
bedding, etc., wherever required shall be incidental
to construction of drain. The Contract unit for
disposal of surplus and unsuitable material beyond
the initial 1000 m lead shall be in accordance with
Clause 301.3.11.
703. GEOSYNTHETICS FOR HIGHWAY

PAVEMENTS
703.1. Scope
This work shall consist of laying

geosynthetic materials over existing bituminous
surface, including preparation of surface and joining,
stitching or overlapping of geosynethetic fabric etc.,
as part of highway pavement strengthening in layers
as shown on drawings.
703.2. Paving Fabrics
703.2.1. Description : This work shall

consist of furnishing and placing as asphalt/bitumen
overlay textile (paving fabric) beneath pavement
overlay or between pavement layers to provide a
water resistant membrane and crack retarding layer.
Page 666 of 1427

703.3. Material Requirements
703.3.1 Paving fabric: The paving fabric

will be a nonwoven heat set material consisting of at
least 85 per cent by weight polyolefins, polyesters or
polyamides. The paving fabric shall be resistant to
chemical attack, rot and mildew and shall have no
tears or defects which will adversely, alter its
physical properties. The fabric shall be specifically
designed for pavement applications and be heat
bonded only on one side to reduce bleed-through of
tack coat during installation. The fabric shall meet
the physical requirements of Table 704-2. Heavy
duty paving fabrics should be used in areas
experiencing unusally high impact forces or heavy
loads such as airport runways and taxiways :
Table 704.2. Physical Requirements-Paving
Fabrics
Property Units Standard

Requirements
Tensile Strength Kg 36.3
Elongation % 50
Asphalt Retention Kg/10sq.m. 10
Melting Point °C 150
Surface Texture - Heat bonded on
one side only
Notes :
1. Certification of conformance from paving
fabric manufacturer may be required
2. All numerical values represent minimum
average roll values (average of test results
Page 667 of 1427

from any sampled roll in 2 lot shall meet or
exceed the minimum values) in weaker
principal direction. Lot shall be sampled
according to ASTM D 4354. “Practice for
Sampling of Geosynthetics for Testing”.
3. Conformance of paving fabrics to

specification property requirements shall he
determined as per ASTM D 4579. “Practice
for Determining the Specification
Conformance of Geosynthetics”.
703.3.2. Tack coat: The tack coat used to

impregnate the fabric and bond the fabric to the
pavement shall be a paving grade Bitumen of 80-100
penetration. A cationic or anionic emulsion may be
used as approved by the Engineer. The use of
cutbacks or emulsions which contain solvents shall
not be used.
703.4. Construction and installation

Requirements
703.4.1. Shipment and storage : The paving

fabric shall be kept dry and wrapped such that it is
protected from the elements during shipping and
storage. At no time shall the paving fabric be
exposed to ultraviolet light for a period exceeding
fourteen days. Paving fabric rolls shall be stored in a
manner which protects them from the elements. If
stored outdoors, they shall be elevated and protected
with a waterproof cover. The paving fabric shall be
Page 668 of 1427

labeled as per ASTM D 4873, “Guide for
identification, storage, and handling of geotextiles”.
703.4.2. Weather limitations : Minimum air

and pavement temperature shall be at least 10°C and
rising for placement of bitumen and shall be at least
15°C and rising for placement bitumen emulsion.
Neither bitumen tack coat nor paving fabric shall be
placed when weather conditions, in the opinion of
the Engineer are not suitable.
703.4.3. Surface preparation : The

pavement surface shall be thoroughly cleaned of all
dirt, water, and oil to the satisfaction of the Engineer.
(Tracks 3 mm wide or greater shall be cleaned and
filled with suitable bituminous material or by a
method approved by the Engineer Crack filling
material shall be allowed to cure prior to paving
fabric placement. Potholes and other pavement
distress shall be repaired. Repairs shall be performed
703.4.4. Tack coat application : The tack

coat shall be spread by means of a calibrated
distributor spray bar. Hand spraying and brush
application may be used in locations of fabric
overlap. Every effort shall be made to keep hand
spraying to a minimum. The tack coat shall be
applied, uniformly to the prepared dry pavement
surface at the rate of 1 kg/sq.m. or as recommended
by the paving fabric manufacturer and approved by
the Engineer. When using emulsions, the application
Page 669 of 1427

rate must be increased as directed by the Engineer to
offset the water content of the emulsion. Within
street intersections, on steep grades, or in other zones
where vehicle speed chances are common place, the
normal application rate shall be reduced by about 20
per cent as directed by the Engineer. The tack coat
application rate must be sufficient to saturate the
fabric and to bond the fabric to the existing
pavement surface.
The temperature of the tack coat shall be
sufficiently high to permit a uniform spray pattern.
For bitumen, tie minimum temperature shall be
140°C. To avoid damage to the fabric, distributor
tank temperatures shall not exceed 160°C. For
bitumen emulsions, the distributor tank temperatures
shall be maintained between 55°C and 70°C.
The target width of tack coat application
shall be equal to the paving fabric width plus 150
mm. The tack coat shall be applied only as far in
advance of paving fabric installation as is
appropriate to ensure a tacky surface at the time of
paving fabric placement. Traffic shall not be allowed
on the tack coat. Excess tack coat shall be cleaned
Page 670 of 1427

from the pavement.
703.4.5. Paving fabric placement: The

paving fabric shall be placed onto the tack coat using
mechanical or manual laydown equipment capable
of providing a smooth installation with a minimum
amount of wrinkling or folding. The paving fabric
shall be placed prior to the tack coat cooling and
losing tackiness. Paving fabric shall not be installed
in areas where the overlay asphalt tapers to a
thickness of less than 40 mm. Excess paving fabric
which extends beyond the edge of existing pavement
or areas of tack coat application shall be trimmed
and removed. When bitumen emulsions are used, the
emulsion shall be allowed to cure properly such that
essentially no water moisture remains prior to
placing the paving fabric. Wrinkles or folds in
excess of 25 mm shall be slit and laid flat. All
transverse joints and slit folds or wrinkles shall be
shingle-lapped in the direction of the paving
operation. Brooming and/or pneumatic rolling will
be required to maximize paving fabric contact with
the pavement surface. Additional hand-placed tack
coat may be required at laps and repairs as
determined by the Engineer to satisfy bitumen
retention of the lapped paving fabric. All areas with
paving fabrics placed will be paved the same day.
No traffic except necessary construction equipment
will be allowed to drive on the paving fabric.
Turning of the paver and other vehicles shall
be done gradually and kept to a minimum to avoid
movement and damage to the paving fabric. Abrupt
Page 671 of 1427

starts and stops shall also be avoided. Damaged
fabric shall be removed and replaced with the same
type of fabric. Overlaps shall be single-lapped in the
direction of paving. Additional tack coat shall be
placed between the overlap to satisfy saturation
requirements of the fabric. Overlap shall be
sufficient to ensure full closure of the joint but not
exceed 150m.
703.4.6. Overlay placement: Bituminous
overlay construction shall closely follow fabric
placement. Ali areas in which paving fabric has been
placed will be paved during the same day. Excess
tack coat which bleeds through the paving fabric
shall be removed. Excess tack coat can be removed
by broadcasting hot mix or sand on the paving
fabric.
704. PROTECTION WORKS WITH
GEOSYNTHETICS
704.1. Scope
This work shall consist of laying boulder

Gabions/Mattresses in wraps of Geosynthetics in the
form of bolsters, on slopes of embankments or in
apron. Gabions or Mattresses are also used for stone
spurs. Geotextiles are used for prevention of
migration of fine soil particles.
704.2. Gabions/Mattresses with Geogrids

and Geonets
Mattresses constructed with Geogrids or
Page 672 of 1427

Geonets shall be used for thickness of 300 mm or
above as shown in the drawings. While adopting a
particular size for gabions or mattresses width of the
roll of geogrid/ geonet may be kept in view to
minimise wastage of the geosynthetic in cutting off
pieces. The mesh opening may vary depending on
functional requirement but shall have aperture
between 35 mm and 100 mm. The mesh/net shall
have following characteristics :
Aperture : Rectangular, square or
oval shaped (and not in
diamond, round or
polygonal shape).
Colour : Black
Mechanical : Peak strength not less
than 10 kN/m at maximum
elongation of
Properties : 15 percent. Not more
than 5 per cent elongation at
half
peak load.
Stands/Fabric : Integral joints with
junction strength of 100 per cent of
plain
Form : strands as measured by
GRI-GG3 standards. Material shall
have ISO 9002
certification.
Life : Atleast 8 years in case
of continuous exposure and 5 years
for burned applications
Page 673 of 1427

(defined as capable of
retaining atleast 75 per
cent of its original
strength after the life
span stated).
704.3. Construction
704.3.1. Assembly : Gabion and mattress

boxes shall be assembled in situ, on a level surface.
After fabrication is done in situ they shall be
correctly filled in layers in dense packed state.
The bottom, sides and end panels shall be
erected after removal of all kinks, kept in an upright
position to form rectangular boxes by joining the
sides with connectors of 40 mm x 6 mm size, or by
ring staples. The top corners shall be tie tensioned
from sides to keep it erect for filling. For gabions of
600 mm or more height, suitable cross internal ties
shall be placed in layers of 300 mm connecting
opposite sides in lateral braces tied with polymer
braids of ultra-violet stabilised variety so as to
ensure protection against bulging of the gabions
during filling with stones.
704.3.2. Construction and installation :

The filling of the gabion/ mattress shall be done by
hand in layers so as to minimise voids and achieve
specified density. The stones in contact with the
surface of the geogrids/geonets shall be placed in
such a way that their sharp edges are kept turned
inside so that they do not damage the material of the
Page 674 of 1427

geogrids/ geonets. The opposite panels of the boxes
shall be firmly secured with lateral ties to withstand
the design forces. The bottom of the gabion mesh
shall be secured in a key type excavation for
preventing slide. The space between the gabion and
earthen sides shall be filled with sand and the filling
compacted. In most of the cases design shall be
supplemented with a layer of geotextile under the
gabion/mattress to prevent migration of fines.
704.33. Laying boulder apron in crates :

Mattresses of minimum height 300 mm shall be
used. The typical size of a single continuous unit
shall be 1 m x 5 m size with baffles at 1 m centres.
The size of boulders shall be at least 100 mm or
double the size of the aperture whichever is larger.
The density of boulder filling shall be as stated in the
drawing and the specific gravity of stones not less
than 2.65. Methodology of laying boulders shall be
as per Clause 2503,3. Gabions if placed in the apron
shall be of size 1 m x 5 m in plan with height at least
600 mm, with baffles in 1 m centres.
Gabions or mattresses made with polymer
geogrids/geonets shall always be laid in situ and
shall not he performed, filled and transported to be
dropped in deep waters. Where depth of water is low
or dry bed is available, the boxes shall be filled in
situ. In streams or water body having running
boulders in the bed, the gabions/mattresses shall be
armoured with placement of loose large boulders
alongside the gabion wall to protect
Page 675 of 1427

against impact hit of stray boulders.
Stakes or keying shall always be provided in
the founding recess, where the gabion be located,
especially in case the ground is assessed to be
sloping or yielding type.
7043.4. Groynes or spurs with crates:

Groynes or spurs of gravity retaining variety shall be
constructed using geogrid/geonet gabions placed in
stable configuration one over the other to form a
well. They shall be filled in situ on a shallow depth
of water or dry bed with firm founding and level
strata. The provision of a layer of
geotextile/geocomposite shall be made while placing
the structure if resting over a bed of fine soil to
prevent passage of fines and sinking.
704.3.5. Measurements for payment : The

fabric of geotextile/geocomposite shall be measured
in sq. metres of plan area of actual use (as per
drawing).
The connecting rods or polymer braids shall
be measured in metres. Ring staples shall be
measured in number provided per linear metre.
The boulder fill shall be measured in cubic
metres
The excavation for keying of gabions in the
ground trenches shall be measured in cubic metres.
The backfilling in side trenches shall be
deemed part of the excavation work.
704.3.6. Rate : The cost of Geosynthetic
Page 676 of 1427

material for fabrication of Gabions/Mattresses shall
be all inclusive of supply, transportation and storage.
The contract rate per cubic metre of crate fill
shall consist of cost of boulders and their
transportation.
The contract rate for excavation and
backfilling of trenches, seating trench upto 15 cm
(included in rate), shall include cost of labour, tools
and plant for completion of the work.
The cost of making a crate shall include
preparation of box of geogrid geonet, tensioning and
staking arrangements, tying, internal crossbraids,
etc., for forming of the crates in an engineered
manner and filling the crate by laying boulders. The
cost shall include transportation of material from
store to site.
Wherever composite system using
Geosynthetics with natural material like stone
revetment etc. shall be used, the provision of
measurement and rate as per Clauses 2509 and 2510
are applicable.
Page 677 of 1427

Traffic Signs, Markings and Other
Road Appurtenances
800
Traffic Signs, Markings and Other
Road Appurtenances
Page 678 of 1427

801. TRAFFIC SIGNS
801.1. General
801.1.1. The colour, configuration, size and

location of all traffic signs for highways other than
Expressways shall be in accordance with the code of
Practice for Road Signs, IRC: 67 or as shown on the
drawings. For Expressways, the size of the signs,
letters and their placement shall be as specified in
the Contract drawings and relevant Specifications. In
the absence of any details or for any missing details,
the signs shall be provided as directed by the
Engineer.
801.1.2. The signs shall be either

reflectorised or non-reflectorised as shown on the
drawings or as directed by the Engineer. When they
are of reflectorised type, they shall be of retro-
reflectorised type and made of encapsulated lens
type reflective sheeting vide Clause 801.3, fixed
Over aluminium sheeting as per these Specifications.
801.13. In general, cautionary and mandatory

signs shall be fabricated through process of screen
printing. In regard to informatory signs with
inscriptions, either the message could be printed over
the reflective sheeting, or cut letters of non-reflective
black sheeting used for the purpose which must be
bonded well on the base sheeting as directed by the
Engineer.
Page 679 of 1427

801.2. Materials
The various materials and fabrication of the

traffic signs shall conform to the following
requirements:
801.2.1. Concrete : Concrete shall be of the

grade shown on the Contract drawings or otherwise
801.2.2. Reinforcing steel : Reinforcing

steel shall conform to the requirement of IS: 1786
unless otherwise shown on the drawing.
801.23. Bolts, nuts, washers: High strength

bolts shall conform to IS : 1367 whereas precision
bolts, nuts, etc., shall conform to IS: 1364.
801.2.4. Plates and supports : Plates and

support sections for the signposts shall conform to
IS: 226 and IS: 2062or any other relevant IS
Specifications.
801.2.5. Aluminium: Aluminium sheets

used for sign boards shall be of smooth, hard and
corrosion resistant aluminium alloy conforming to IS
: 736-Material designation 24345 or 1900.
801.2.6. Signs with a maximum side

dimension not exceeding 600 mm shall not be less
than 1.5 mm thick. All others shall be at least 2 mm
thick. The thickness of the sheet shall be related to
Page 680 of 1427

the size of the sign and its support and shall be such
that it does not bend or deform under the prevailing
wind and other loads.
801.2.7. In respect of sign sizes not covered

by IRC:67, the structural details (thickness, etc.)
shall be as per the approved drawings.
801.3. Traffic Signs Having Retro-

reflective Sheeting
801.3.1. General requirements: The retro-

reflective sheeting used on the sign shall consist of
the white or coloured sheeting having a smooth
outer surface which has’ the property of retro-
reflection over its entire surface. It shall be weather-
resistant and show colour fastness. It shall be new
and unused and shall show no evidence of cracking,
scaling, pitting, blistering, edge lifting or curling and
shall have negligible shrinkage or expansion. A
certificate of having tested the sheeting for these
properties in an unprotected outdoor exposure
facing the sun for two years and its having
passed these tests shall be obtained from a reputed
laboratory, by the manufacturer of the sheeting. The
reflective sheeting shall be either of Engineering
Grade material with enclosed lens or of High
Intensity Grade with encapsulated lens. The type of
the sheeting to be used would depend upon the type,
functional hierarchy and importance of the road.
801.3.2. High intensity grade sheeting :
Page 681 of 1427

This sheeting shall be of encapsulated lens type
consisting of spherical glass lens, elements adhered
to a synthetic resin and encapsulated by a flexible,
transparent water-proof plastic having” a smooth
surface. The retro-reflective surface after cleaning
with soap and water and in dry condition shall have
the minimum co-efficient of retro-reflection
(determined in accordance with ASTM Standard
E : 810) as indicated in Table 800-1.
TABLE 800-1. ACCEPTABLE

MINIMUM
COEFFICIENT OF
RETRO-REFLECTION
FOR HIGH INTENSITY
GRADE SHEETING
(CANDELAS PER LUX
PER SQUARE METRE)
Observation Entrance White Yellow Orange

angle Angle
(In degrees) (in degrees)
0.2 -4 250 170 100
0.2 +30 150 100 60
0.5 -4 95 62 30
0.5 +30 65 45 25
When totally wet, the sheeting shall not show

less than 90 per cent of the values of retro-
reflectance indicated in Table 800-1. At the end of 7
years, the sheeting shall retain at least 75 per cent of
its original retro-reflectance.
Page 682 of 1427

801.3.3. Engineering grade sheeting : This
sheeting shall be of enclosed lens type consisting of
microscopic lens elements embedded beneath the
surface of a smooth, flexible, transparent, water-
proof plastic, resulting in a non-exposed lens optical
reflecting system. The retro-reflective surface after
cleaning with soap and water and in dry condition
shall have the minimum coefficient of retro-
reflection (determined in accordance with ASTM
Standard : E-810) as indicated in Table 800-2.
Page 683 of 1427

TABLE 800-2. ACCEPTABLE
MINIMUM
COEFFICIENT OF
RETRO-REFLECTION
FOR ENGINEERING
GRADE SHEETING
(CANDELAS PER LUX
PER SQUARE METRE)
Observation Entrance White Yellow Orange Green

angle Angle
(In degrees) (in degrees)
0.2 -4 70 50 25 9.0
0.2 +30 30 22 7.0 3.5
0.5 -4 30 25 13.5 4.5
0.5 +30 15 13 4.0 2.2
When totally wet, the sheeting shall not show

less than 90 per cent of the values, of retro-reflection
indicated in Table 800-2. At the end of 5 years, the
sheeting shall retain at least 50 per cent of its
original retro-reflectance.
801.3.4. Messages/borders: The messages

(legends, letters, numerals etc.) and borders shall
either be screen-printed or of cut-outs. Screen
printing shall be processed and finished with
materials and in a manner specified by the sheeting
manufacturer. Cut-outs shall be of materials as
specified by the sheeting manufacturer and shall be
bonded with the sheeting in the manner specified
by the manufacturer.
Page 684 of 1427

801.3.5. For screen-printed transparent
coloured areas on while sheeting, the co-efficient of
retro-reflection shall not be less than 50 per cent of
the values of corresponding colour in Tables 800-1
and 800-2, as applicable.
801.3.6. Cut-out messages and borders,

wherever used, shall be made out of retro-reflective
sheeting (as per Clause 801.3.2 or 801.3.3 as appli-
cable), except those in black which shall be of non-
reflective sheeting.
801.3.7. Colour: Unless otherwise specified,

the general colour scheme shall be as stipulated in
IS : 5 “Colour for Ready Mixed Paints” viz.
Blue - IS Colour No. 166:

French Blue
Red - IS Colour No. 537:
Signal Red
Green - IS Colour No. 284:
India Green
Orange - IS Colour No. 591:
Deep Orange.
The Colours shall be durable and uniform in

acceptable hue when viewed in day light or under
normal headlights at night.
801.3.8. Adhesives : The sheeting shall

either have a pressure-sensitive adhesive of the
Page 685 of 1427

aggressive-tack type requiring no heat, solvent or
other preparation for adhesion to a smooth clean
surface, or a tack free adhesive activated by heat,
applied in a heat-vacuum applicator, in a manner
recommended by the sheeting manufacturer. The
adhesive shall be protected by an easily removable
liner (removable by peeling without soaking in water
or other solvent) and shall be suitable for the type of
material of the base plate used for the sign. The
adhesive shall form a durable bond to smooth,
corrosion and weather resistant surface of the base
plate such that it shall not be possible to remove the
sheeting from the sign base in one piece by use of
sharp instrument. In case of
Page 686 of 1427

pressure-sensitive adhesive sheeting, the sheeting
shall be applied in accordance with the
manufacturer’s Specifications. Sheeting with
adhesives requiring use of solvents or other
preparation for adhesive shall be applied strictly in
accordance with the manufacturer’s instructions.
801.3.9. Refurbishment: Where existing

signs are specified for refurbishment, the sheeting
shall have a semi-rigid aluminium backing pre-
coated with aggressive-tack type pressure sensitive
adhesive. The adhesive shall be suitable for the type
of material used for the sign and should thoroughly
bond with that material.
8013,10. Fabrication :
801.3.10.1. Surface to be reflectorised shall

be effectively prepared to receive the retro-reflective
sheeting. The aluminium sheeting shall be de-
greased either by acid or hot alkaline etching and all
scale/dust removed to obtain a smooth plain surface
before the application of retro-reflective sheeting. If
the surface is rough, approved surface primer may be
used. After cleaning, metal shall not be handled,
except by suitable device or clean canvas gloves,
between all cleaning and preparation operation and
application of reflective sheeting/primer. There shall
be no opportunity for metal to come in contact with
grease, oil or other contaminants prior to the
application of retro-reflective sheeting.
Page 687 of 1427

801.3.10.2. Complete sheets of the material
shall be used on the signs except where it is
unavoidable; at splices, sheeting with pressure
sensitive adhesives shall be overlapped not less than
5 mm. Sheeting with heat-activated adhesives may
be spliced with an overlap not less than 5 mm or
butted with a gap not exceeding 0.75 mm. Where
screen printing with transparent colours is proposed,
only butt jointing shall be used. The material shall
cover the sign surface evenly and shall be free from
twists, cracks and folds. Cut-outs to produce legends
and borders shall be bonded with the sheeting in the
manner specified by the manufacturer.
801.3.11. Warranty and durability : The

Contractor shall obtain from the manufacturer a
seven-year warranty for satisfactory field
performance including stipulated retro-reflectance of
the retro-reflective sheeting of high intensity grade
and a five year warranty for the adhesive sheeting of
engineering grade, and submit the same to the
Engineer. In addition, a seven year and a five year
warranty for satisfactory in-field performance of the
finished sign with retro-reflective sheeting of high
intensity grade and engineering grade respectively,
inclusive of the screen printed or cut out
letters/legends and their bonding to the retro-
reflective sheeting shall be obtained from the
Contractor/supplier and passed on to the Engineer.
The Contractor/supplier shall also furnish a
certification that the signs and materials supplied
against the assigned work meets all the stipulated
Page 688 of 1427

requirements and carry the stipulated warranty.
Processed and applied in accordance with
recommended procedures, the reflective material
shall be weather resistant and, following cleaning,
shall show no appreciable discolouration, cracking,
blistering or dimensional change and shall not have
less than SO per cent of the specified minimum
reflective intensity values (Tables 800-1 and 800-2)
when subjected to accelerated weathering for 10QO
hours, using type E or EH Weatherometer
(AASHTO Designation M 268).
Page 689 of 1427

801.4. Installation
801.4.1. Sign posts, their foundations and

sign mountings shall be so constructed as to hold
these in a proper and permanent position against the
normal storm wind loads or displacement by
vandalism. Normally, signs with an area upto 0.9 sq.
m. shall be mounted on a single post, and for greater
area two or more supports shall be provided. Sign
supports may be of mild steel, reinforced concrete or
galvanised iron (G.I). Post end(s) shall be firmly
fixed to the ground by means of property designed
foundation. The work of foundation shall conform to
relevant Specifications as specified
801.4.2. All components of signs and

supports, other than the reflective portion and G.I.
posts shall be thoroughly descaled, cleaned primed
and painted with two coats of epoxy paint. Any pan
of mild steel (M.S.) post below ground shall be
painted with three coats of red lead paint.
801.4.3. The signs shall be fixed to the posts

by welding in the case of steel posts and by bolts and
washers of suitable size in the case of reinforced
concrete or G.I. posts. After the nuts have been
tightened, the tails of the bolts shall be furred over
with a hammer to prevent removal.
The measurement of standard cautionary,
Page 690 of 1427

mandatory and information signs shall be in numbers
of different types of signs supplied and fixed, while
for direction and place identification signs, these
shall be measured by area in square metres.
801.6. Rate
The Contract unit rate shall be payment in

full for the cost of making the road sign, including
all materials, installing ii at the site and incidentals to
complete the work in accordance with the
Specifications.
802. OVERHEAD SIGNS

802.1. General
802.1.1. Overhead signs may be used in lieu

of, or as an adjunct to, ground signs where the
situation so warrants for proper information and
guidance of the road user. The following conditions
may be considered while deciding about the
provision of overhead signs:
(1) Traffic volume at or near capacity

(2) Complex interchange design
(3) Three or more lanes in each direction
(4) Restricted light distance
(5) Closely spaced interchanges
(6) Multi-lane exits
(7) Large percentage of commercial
vehicles
(8) High speed traffic
Page 691 of 1427

(9) Consistency of sign message location
through a series of interchanges
(10) Insufficient space for ground mounted
signs
Page 692 of 1427

(11) Background of street lighting
(12) Distances of important places enroute
highways at suitable intervals.
802.1.2. From safety and aesthetic

standpoints, overhead signs shall be mounted on
overhead bridge structures wherever possible. Where
these are required to be provided at some other
locations, the support system should be properly
designed based on sound engineering principles, to
safely sustain the dead load, live load and wind load
on the completed sign system. For this purpose, the
overhead signs shall be designed to withstand a wind
loading of 150 kg/m2 normal to the face of the sign,
and 30 kg/m2 transverse to the face of the sign. In
addition to the dead load of the structure, walkway
loading of 250 kg concentrated live load shall also
be considered for the design of the overhead sign
structure.
802.2. Height
Overhead signs shall provide a vertical

clearance of not less than 5.5 m over the entire width
of the pavement and shoulders except where a lesser
vertical clearance is used for the design of other
structures. The vertical clearance to overhead sign
structures or supports need not be greater than 300
mm in excess of the minimum design clearance of
other structures.
Page 693 of 1427

802.3. Lateral Clearance
802.3.1. The minimum clearance outside the

usable roadway shoulder for expressway signs
mounted at the road side or for overhead sign
supports either to the right or left side of the roadway
shall be 1.80 m. This minimum clearance of 1.80 m
shall also apply outside of an uncountable kerb.
Where practicable, a sign should not be less than 3 m
from the edge of the nearest traffic lane. Large guide
signs should be farther removed preferably 9 m or
more from the nearest traffic lane, unless otherwise
specified. Lesser clearances, but not generally less
than 1.80 m, may be used on connecting roadways or
ramps at inter-changes.
802.3.2. Where a median is 3.6 m or less in

width, consideration should be given to spanning
over both roadways without a central support. Where
overhead sign supports cannot be placed at a safe
distance away from the line of traffic or in an
otherwise protected site, y should either be so
designed as to minimise the impact forces or protect
motorists adequately by a physical barrier or guard
rail of suitable design.
802.4. Number of Signs at an Overhead

Installation
In no case .should there be more than three

signs displayed at any one location, including
regulatory or warning signs, either on the overhead
Page 694 of 1427

structure or on its support.
802.5. Materials for Overhead Sign and

Support Structures
802.5.1. Aluminium alloy or galvanized steel

to be used as truss design supports shall conform to
relevant IS. These shall be of sections and type as
per structural design requirements as shown on the
plans.
8015.2. After steel trusses have been

fabricated and all required holes punched or drilled
on both the horizontal truss units and the vertical and
support units, they shall be galvanized in accordance
with IS Specifications.
802.5.3. Where aluminium sheets are used

for road signs, they shall be of smooth, hard and
corrosion resistant aluminium alloy conforming to IS
736- Material Designation 24345 or 1900. The
thickness of sheet shall be related to the size of the
sign with minimum thickness of sheet as 1.5 mm.
802.5.4. High strength bolts shall conform

to IS: 1367 whereas precision bolts, nuts etc. shall
conform to IS: 1364.
802.5.5. Plates and support sections for sign

posts shall conform to !S: 226 and IS: 2062.
802.5.6. The overhead signs shall be
Page 695 of 1427

reflectorised with high intensity retro-reflective
sheeting preferably of encapsulated lens type.
802.6. Size, Locations, etc. of Signs
802.6.1. The size of the signs, letters and

their placement shall be as specified in the Contract
drawings and Specifications.
802.6.2. In the absence of details or for any

missing details in the Contract documents, the signs
shall be provided .as directed by the Engineer.
802.7. Installation
802.7.1. The supporting structure and signs

shall be fabricated and erected as per details given in
the plans.
802.7.2. Sign posts, their foundations and

sign mountings shall be so constructed as to hold
signs in a proper and permanent position to
adequately resist swaying in the wind or
displacement by vandalism.
802.7.3. The work of construction of

foundation for sign supports including excavation
and backfill, forms, steel reinforcement, concrete
and its placement, shall conform to the relevant
Specifications given in these Specifications.
802.7.4. The structures shall be erected with
Page 696 of 1427

the specified camber and in such a manner as to
prevent excessive stresses, injury and defacement.
802.7.5. Brackets shall be provided for

mounting signs of the type to be supported by the
structure. For better visibility, they shall be
adjustable to permit mounting the sign faces at any
angle between a truly vertical position and three
degree from vertical. This angle shall be obtained
by rotating the front lower edge of the sign forward.
All brackets shall be of a length equal to the heights
of the signs being supported.
Page 697 of 1427

802.7.6. Before erecting support structures,
the bottom of each base plate shall be protected with
an approved material which will adequately prevent
any harmful reaction between the plate and the
concrete.
802.7.7. The end supports shall be plumbed

by the use of levelling nuts and the space between
the foundation and base plate shall be completely
filled with an anti-shrink grout.
802.7.8. Anchor bolts for sign supports shall

be set to proper locations and elevation with
templates and carefully checked after construction
of the sign foundation and before the concrete has
set.
802.7.9. All nuts on aluminium trusses,

except those used on the flanges, shall be tightened
only until they are snug. This includes the nuts on
the anchor bolts. A thread lubricant shall be used
with each aluminium nut.
802.7.10. All nuts on galvanized steel

trusses, with the exception of high strength bolt
connections, shall be tightened only to a snug
condition.
802.7.11. Field welding shall not be

permitted.
802.7.12. After installation of signs is
Page 698 of 1427

complete, the sign shall be inspected by the
Engineer. If specular reflection is apparent on any
sign, its positioning shall be adjusted by the
Contractor to eliminate or minimize this condition.
802.8.1. Aluminium or steel overhead sign

structure will be measured for payment by the
specific unit (each) complete in place or for each
component of the overhead sign structure as
indicated in the Bill of Quantities and the detailed
drawing(s).
802.8.2. Flat sheet aluminium signs with

retro-reflective sheeting thereon shall be measured
for payment by the square metre for each thickness,
complete in place.
802.9. Rate
802.9.1. The structural steel part of the

overhead sign shall be measured in tonnes while the
sign board shall be measured in sq.m. Other items
like excavation for foundation and concrete in
foundation to be measured and paid in cu. m.
separately. The Contract unit rate for overhead sign
structure shall be payment in full compensation for
furnishing all labour, materials, tools, equipment,
excavation, fabrication and installation and all other
incidental costs necessary to complete the work to
the Specifications.
Page 699 of 1427

aluminium sheet signs shall include the cost of
making the sign including all materials and fixing
the same in position and all other incidental costs
necessary to complete the work to the
Specifications.
Page 700 of 1427

803. ROAD MARKINGS
803.1. General
The colour, width and layout of road

markings shall be in accordance with the Code of
Practice for Road Markings with paints. IRC : 35,
and as specified in the drawings or as directed by the
Engineer.
803.2. Materials
Road markings shall be of ordinary road

marking paint, hot applied thermoplastic compound,
or reflectorised paint as specified in the item and the
material shall meet the requirements as specified
below.
803.3. Ordinary Road Marking Paint
803.3.1. Ordinary paint used for road

marking shall conform to Grade I as per IS: 164.
803.3.2. The road marking shall preferably

be laid with appropriate road marking machinery.
803.3.3. Laying thickness of road marking

paint shall be as specified by the Engineer.
803.4. Hot Applied Thermoplastic Road

Marking
803.4.1. General :
Page 701 of 1427

(i) The work under this section consists of
marking traffic stripes using a
thermoplastic compound meeting the
requirements specified herein.
(ii) The thermoplastic compound shall be
screeded/extruded on to the pavement
surface in a molten stale by suitable
machine capable of controlled
preparation and laying with surface
application of glass beads at a specific
rate. Upon cooling to ambient pavement
temperature, it shall produce an adherent
pavement marking of specified thickness
and width and capable of resisting
deformation by traffic*
(iii) The colour of the .compound shall be
white or yellow (IS colour No. 356) as
specified in the drawings or as directed
by the Engineer.
(iv) Where the compound is to be applied to
cement concrete pavement, a sealing
primer as recommended by the
manufacturer, shall be applied to the
pavement in advance of placing of the
stripes to ensure proper bonding of the
compound. On new concrete surface any
laitance and/or curing compound shall be
removed before the markings are applied.
803.4.2. Thermoplastic Material
Page 702 of 1427

803.4.2.1. General : The thermoplastic
material shall be homogeneously composed of
aggregate, pigment, resins and glass reflectorizing
beads.
803.4.2.2. Requirements :
(i) Composition : The pigment, beads, and

aggregate shall be uniformly dispersed in
the resin. The material shall be free from
all skins, din and foreign objects and shall
comply with requirements indicated in
Table 800-3.
TABLE 800-3. PROPORTIONS OF

CONSTITUENTS OF MARKING MATERIAL
(Percentage by weight)
Component White
Binder 18.0 min.
Glass Beads 30-40
Titanium Dioxide 10.0 min.
Calcium Carbonate and
Inert Fillers 42.0 max.
Yellow Pigments —
Note : Amount of yellow pigment, calcium
carbonate and inert fillers shall be at the
option of the manufacturer, provided all
other requirements of this Specification
are met.
(ii) Properties: The properties of
Page 703 of 1427

thermoplastic material when tested in
accordance with ASTM D36/BS-3262-
(Pan I) shall be as below:
(a) Luminance :
White : Daylight luminance at 45
degrees 65 per cent min. as per
AASHTO M 249
Yellow : Daylight luminance at 45
degrces-45 per cent min. as per
AASHTO M 249
(b) Drying time : When applied at a
temperature specified by the
manufacturer and to the required
thickness, the material shall set to
bear traffic in not. more than IS
minutes.
(c) Skid resistance : not less than 45
as per BS 6044.
(d) Cracking resistance at low
temperature : The material shall
show no cracks on application to
concrete blocks.
(e) Softening point : 102.5 t 9.5’ C as
per ASTM D 36.
(f) Flow resistance : Not more than
25 per cent as per AASHTO M
249.
(g) Yellowness index (for white
thermoplastic paint): not more
than 0.12 as per AASHTO M 249
Page 704 of 1427

(iii) Storage life : The material shall meet the
requirements of these Specifications for a
period of one year. The thermoplastic
material must also melt uniformly with
no evidence of skins or unmelled panicles
for the one year storage period. Any
material not meeting the above
requirements shall be replaced by the
manufacturer/ supplier/Contractor.
(iv) Reflectorisation : Shall be achieved by

incorporation of beads, the grading and
other properties of the beads shall be as
specified in Clause 803.4.3.
(v) Marking : Each container of the

thermoplastic material shall be clearly
and indelibly marked with the following
information:
1. The name, trade mark or other means

of identification of manufacturer
2. Batch number
3. Date of manufacture
4. Colour (white or yellow)
5. Maximum application temperature
and maximum safe healing
temperature.
(vi) Sampling and testing : The

thermoplastic material shall be sampled
and tested in accordance with the
Page 705 of 1427

appropriate ASTM/BS method. The
Contractor shall furnish to the Employer
a copy of certified test reports from the
manufacturers of the thermoplastic
material showing results of all tests
specified herein and shall certify that the
material meets all requirements of this
Specification.
803.4.3. Reflectorising glass beads
803.4.3.1. General : This Specification

covers two types of glass beads to be used for the
production of reflectorised pavement markings.
Type 1 beads are these which are a

constituent of the basic thermoplastic compound
vide Table 800-3 and Type 1 beads are those which
are to be sprayed on the surface vide Clause 803.6.3.
803.4.3.2. The glass beads shall be

transparent, colourless and free from milkiness, dark
particles and excessive air inclusions.
These shall conform to the requirements

spelt out in Clause 803.4.3.3.
803.4.3.3. Specific requirements
A. Gradation: The glass beads shall meet

the gradation requirements for the two types as given
in Table 800-4.
Page 706 of 1427

TABLE 800-4. GRADATION REQUIREMENTS
FOR GLASS BEADS
Percent retained
Sieve size
Type1 T
1.18 mm 0 to 3
850 micron 5 to 20 0
600 -do- - 5
425 -do- 65 to 95
300 -do- - 30
180 -do- 0 to 10 10
below 180 micron 0
Page 707 of 1427

B. Roundness: The glass beads shall have a
minimum of 70 per cent true spheres.
C. Refractive index: The glass beads shall
have a minimum refractive index of
1.50.
D. Free flowing properties : The glass
beads shall be free of hard lumps and
clusters and shall dispense readily
under any conditions suitable for paint
striping. They shall pass the free flow
test.
803.4.3.4. Test methods: The specific

requirements shall be tested with the following
methods:
(i) Free-flow test: Spread 100 grams of

beads evenly in a 100 mm diameter
glass dish. Place the dish in a 250mm
inside diameter desiccator which is
filled within .25 mm of the top of a
desiccator plate with sulphuric acid
water solution (specific gravity 1.10).
Cover the desiccator and let it stand for
4 hours at 20 to 29 degree C. Remove
sample from desiccator, transfer beads
to a pan and inspect for lumps or
clusters. Then pour beads into a clean,
dry glass funnel having a 100 mm stem
and 6 mm orifice. If necessary, initiate
flow by lightly tapping the funnel. The
glass spheres shall be essentially free of
Page 708 of 1427

lumps and clusters and shall flow freely
through the funnel.
(ii) The requirements of gradation,
roundness and refractive index of glass
beads and the amount of glass beads in
the compound shall be tested as per BS
6088 and BS 3262 (Part I).
(iii) The Contractor shall furnish to the
Employer a copy of certified test
reports from the manufacturer of glass
beads obtained from a reputed
laboratory showing results of all tests
specified herein and shall certify that
the material meets all requirements of
this Specification. However, if so
required, these tests may be carried out
803.4.4. Application properties of

thermoplastic material
803.4.4.1. The thermoplastic material shall

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

application temperatures, shall not exude fumes,
which are toxic, obnoxious or injurious to
persons or property.
Page 709 of 1427

803.4.5. Preparation:
(i) The material shall be melted in

accordance with the manufacturer’s
instructions in a heater fitted with a
mechanical stirrer to give a smooth
consistency 10 the thermoplastic
material to avoid local overheating. The
temperature of the mass shall be within
the range specified by the
manufacturer, and shall on no account
be allowed to exceed the maximum
temperature stated by the manufacturer.
The molten material should be used as
expeditiously as possible and for
thermoplastic material which has
natural binders or is otherwise sensitive
to prolonged heating, the material shall
not be maintained in a molten condition
for more than 4 hours.
(ii) After transfer to the laying equipment,
the material shall be maintained within
the temperature range specified .’ay the
manufacturer for achieving the desired
consistency for laying.
803.4.6. Properties of finished road

marking :
(a) The stripe shall not be slippery when

wet.
Page 710 of 1427

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

the Specification by the manufacturers and approved
by the Engineer. Reflectorising glass beads for
reflectorising paints where used shall conform to the
requirement of Clause 803.4.3
803.6. Application
803.6.1. Marking shall be done by machine.

For locations where painting cannot be done by
Page 711 of 1427

machine, approved manual methods shall be used
with prior approval of the Engineer. The Contractor
shall maintain control over traffic while painting
operations are in progress so as to cause minimuro
inconvenience to traffic compatible with protecting
the workmen.
803.6.2. The thermoplastic material shall

be applied hot either by screeding or extrusion
process. After transfer to the laying apparatus, the
material shall be laid at a temperature within the
range specified by the manufacturer for the
particular method of laying being used. The paint
shall be applied using a screed or extrusion machine.
803.6.3. The pavement temperature shall not

be less than 10°C during application. All surfaces to
be marked shall be thoroughly cleaned of all dust,
dirt, grease, oil and all other foreign matter
before application of the paint.
The material, when formed into traffic

stripes, must be readily renewable by placing an
overlay of new material directly over an old line of
compatible material. Such new material shall so
bond itself to the old line that no splitting or
separation takes place.
Thermoplastic paint shall be applied in

intermittent or continuous lines of uniform thickness
of at least 2.5 mm unless specified otherwise. Where
arrows or letters are to be
Page 712 of 1427

provided, thermoplastic compound may be hand-
sprayed. In addition 10 the beads included in the
material, a further quantity of glass beads of Type 2,
conforming to the above noted Specification shall be
sprayed uniformly into a mono-layer on to the hot
paint line in quick succession of the paint spraying
operation. The glass beads shall be applied at the rate
of 250 grams per square metre area.
803.6.4. The minimum thickness specified

is exclusive of surface applied glass beads. The
method of thickness measurement shall be in
accordance with Appendices B and C of BS - 3262
(Part 3).
803.6.5. The finished lines shall be free from

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

measured in sq. metres of actual area marked
(excluding the gaps, if any).
803.7.2. In respect of markings like

directional arrows and lettering, etc., the
measurement shall be by numbers.
803.8. Rate
Page 713 of 1427

The Contract unit rate for road markings
shall be payment In full compensation for furnishing
all labour, materials, tools, equipment including all
incidental costs necessary for carrying out the work
at the site conforming to these Specifications
complete as per the approved drawing(s) or as
directed by the Engineer and all other incidental
costs necessary to complete the work to these
Specifications.
804. HECTOMETRE/KILOMETRE
STONES
804.1. General
The work covers the supply, painting,
lettering and fixing of distance measurement stones
and shall include:
(i) Hectometre stones

(ii) Kilometre stones
(iii) 5th Kilometre stones
804.2. The dimensions of the stones and the

size, colour, arrangement of letters and script shall
be as per IRC : 26 “Type Designs for 200 Metre
Stones” and IRC: 8 “Type Design for Highway
Kilometre Stones”.
804.3. The hectometre/kilometre stones

may be made of loca1 stones, concrete or any other
material available locally and approved by the
Page 714 of 1427

Engineer. The stones Shall be bedded into the
ground with adequate foundations as indicated in
the drawings or in the relevant I.R.C. Specifications
or as directed by the Engineer. The orientation and
location of the stones shall be as indicated in the
drawings or in the relevant I.R.C. Specifications or
Page 715 of 1427

The measurement will be in numbers of 200

metre, kilometre and 5th kilometre stones fixed at
site.
804.5. Rate
The Contract unit rate for

hectomeire/kilometre/5th kilometre stones shall be
payment in full compensation for furnishing all
labour, materials, tools, equipment and making the
stones, painting and lettering and fixing at site and
all other incidental costs necessary to complete the
work to these Specifications.
805. ROAD DELINEATORS
805.1. General
The work covers supplying and fixing
roadway indicators, hazard markers and object
markers.
805.2. The design, materials to be used and

the location of the road delineators shall conform
to Recommended Practice for Road Delineators,
IRC: 79, and to relevant drawings or as otherwise
The measurement shall be made in numbers
Page 716 of 1427

of delineators fixed at site.
805.4. Rate
The Contract unit rate for Road Delineators

shall be payment in full compensation for furnishing
all labour, materials, tools, equipment for preparing,
supplying and fixing at site and all other incidental
costs necessary to complete the work to these
Specifications.
806. BOUNDARY STONES
806.1. General
The work comprises of supplying and fixing

boundary stones as per designs and Specifications
given in IRC: 25.’Type Designs for Boundary
Stones” and at locations indicated in the drawing or
The measurement shall be made in numbers

of boundary stones fixed at site.
806.3. Rate
The Contract unit rate for boundary stones

shall be payment in full compensation for furnishing
all labour, materials, tools, equipment for preparing,
supplying and fixing and all other incidental costs
Page 717 of 1427

necessary to complete die work to these
Specifications.
Page 718 of 1427

807. FENCING
807.1. General
The work comprises of fixing Mild Steel

(M.S.) posts and providing barbed wire fencing
including necessary stays and entry gates as shown
in the drawing (s) and as directed by the Engineer.
Traffic Signs and Appurtenances
807.2. The M.S. posts shall conform to

IS:226 and shall be of angle iron of size indicated in
the drawings. The angle iron shall be embedded in
concrete to a sufficient depth below ground as
indicated in the drawings. The steel shall be
fabricated and painted to conform to Section 1900
of these Specifications.
807.3. The barbed wire shall be of galvanised

iron and shall conform to IS:278.
807.4. Entry gate(s) shall be made of M.S.

rods or other metal as per the design shown in the
drawing(s).

The measurement shall be in running metre
of fencing including the entry gates.
807.6. Rate
Page 719 of 1427

The Contract unit rate for fencing shall be
payment in full compensation for furnishing all
labour, materials, tools, equipment for fabrication
and fixing at site and all other incidental costs
necessary to complete the work to these
Specifications.
808. TUBULAR STEEL RAILING
808.1. General
The work shall consist of supplying, fixing

and erecting tubular steel railings as shown on the
drawings and as directed by the Engineer.
808.2. The railings shall be of tubular steel

in conformance to IS: 1239. The. fabrication and
painting except for the final coat shall be completed
before dispatch to the site. Prior to the painting, all
surfaces shall be grit blasted to the satisfaction of
the Engineer and pickled. The priming coat of paint
shall be applied as soon as the steel has dried.
808.3. The posts shall be vertical and of the
type as shown in the drawing with a tolerance not
exceeding 6 mm in a length of 3 m. The railing
shall be erected true to line and grade.
The railing shall be measured in linear metre

from end to end along the face of the railing,
including end and intermediate posts, with no
Page 720 of 1427

deductions for gaps as shown on the drawings.
Page 721 of 1427

808.5. Rate
The Contract unit rate for Tubular Steel

Railing shall be payment in full compensation for
furnishing all labour, materials, tools, equipment and
plant required for fabrication, connection, oiling,
painting, temporary erection, inspection, test and
final erection at site and all other incidental costs
necessary to complete the work to these
Specifications.
809. CONCRETE CRASH BARRIER
809.1. General
809.1.1. This work shall consist of

construction, provision and installation of concrete
crash barrier at the edges of the road and median at
locations and of dimensions as shown on the
drawings or as directed by the Engineer.
809.1.2. Concrete barrier shall generally be

located on approaches to bridge structures, at
locations where the embankment height is more than
3 metres and at horizontal curves.
809.2. Materials
809.2.1. All materials shall conform to

Section 1000-Materials for Structures as applicable,
and relevant Clauses in Section 1600 shall govern
the steel reinforcement. The concrete barriers shall
Page 722 of 1427

be constructed either by the “cast-in-place with fixed
forms” method or the “extrusion or slip form”
method or a combination thereof at the Contractor’s
option with the approval of the Engineer. Where
“extrusion or slip form” method is adopted, full
details of the method and literature shall be
furnished.
809.2.2. Concrete barriers shall be

constructed with M : 20 grade concrete and with
High Yield Strength deformed reinforcement
conforming to IRC: 21.
809.2.3. An expansion joint with pre-

moulded asphalt filler board shall be provided at the
junction of crash barrier on structure and crash
barrier on the fill. The crash barrier on the fill shall
be constructed in pieces of length not exceeding 20
m, with, pre-moulded asphalt filler board joints.
809.3.1. The location of crash barrier shall be

strictly adhered to as shown on the drawing and as
directed by the Engineer. Concrete crash barriers
shall present a smooth, uniform appearance in their
final position, conforming to the horizontal and
vertical lines shown on the plans or as ordered by the
Engineer and shall be free of lumps, sags or other
irregularities. The top and exposed faces of the
barriers shall conform to the specified tolerances, as
defined in Clause 809.4, when tested with 3 m
Page 723 of 1427

straight edge, laid on the surface.
809.3.2. When concrete barriers are to be
constructed on recently completed bridges, the
height of the barriers shall be adjusted to compensate
for the camber and dead load deflection of the
superstructure. The amount of adjustment shall be
determined by the Engineer and shall be ordered
before the concrete is placed. Such barriers shall
Page 724 of 1427

be placed after form work has been released and as
long after the superstructure construction as possible
without hampering the progress of the work.
809.3.3. Backfilling to the concrete barriers

shall be compacted in layers to the compaction of the
surrounding earthwork.
809.4. Tolerance The overall horizontal

alignment of rails shall not depart from the road
alignment by more than ± 30 mm, nor deviate in any
two successive lengths from straight by more than 6
mm and the faces shall not vary more than 12 mm
from the edge of a 3 m straight edge. Barriers snail
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.

All barriers will be measured by linear
metres of completed and accepted length in place,
corresponding end to end along the face of concrete
barriers including approach and departure ends.
809.6. Rate
The Contract unit rate shall include full

compensation for furnishing all labour, materials,
tools, equipment and incidental costs necessary for
doing all the work involved in constructing the
concrete barrier complete in place in all respects as
per these Specifications.
Page 725 of 1427

810. METAL BEAM CRASH BARRIER
810.1. General
810.1.1. This work shall consist of

furnishing and erection of metal beam crash barrier
of dimensions and at locations as shown on the
drawing (s) or as directed by the Engineer.
810.1.2. Metal beam crash barrier shall

generally be located on approaches to bridge
structures, at locations where the embankment height
is more than 3 metres and at horizontal curves.
810.2. Materials
810.2.1. Metal beam rail shall be corrugated

sheet steel beams of the class, type, section and
thickness indicated on the plans. Railing posts shall
be made of steel of the section, weight and length as
shown on the plans. All complete steel rail elements,
terminal sections, posts, bolts, nuts, hardware and
other steel fittings shall be galvanised. All elements
of the railing shall be free from abrasions, rough or
sharp edges and shall not be kinked, twisted or bent.
810.2.2. Steel beam elements and terminal

sections shall be galvanised (zinc coated, 0.55
kg per square metre,’ minimum single spot) unless
otherwise specified. The galvanising on all other
steel parts shall conform to the relevant IS
Page 726 of 1427

Specifications. All fittings (bolts, nuts, washers)
shall conform to the IS : 1367 and IS :
Page 727 of 1427

1364. All galvanizing shall be done after
fabrication.
810.2.3. Concrete for bedding and anchor

assembly shall conform to Section 1700 of. these
Specifications.
810.3.1. The line and grade of railing shall

be true to that shown on the plans. The railing shall
be carefully adjusted prior to fixing in place, to
ensure proper matching at abutting joints and correct
alignment and camber throughout their length. Holes
for field connections shall be drilled with the railing
in place in the structure at proper grade and
alignment.
810.3.2. Unless otherwise specified on the

drawing, railing steel posts shall be given one shop
coat of paint (primer) and three coats of paint on
structural steel after erection, if the sections are not
galvanised. Any pan of assembly below ground shall
be painted with three coats of red lead paint.
810.3.3. Splices and end connections

shall be of the type and designs specified or
shown on the plans and shall be of such strength as
to develop full design strength of the rail elements.
810.4. Installation of Posts
Page 728 of 1427

810.4.1. Holes shall be dug or drilled to the
depth indicated on the plans or posts may be driven
by approved methods and equipment, provided these
are erected in proper position and are free from
distortion and burring or any other damage.
810.4.2. All post holes that are dug or

drilled shall be of such size as will permit proper
setting of the-posts and allow sufficient room for
backfilling and tapping.
810.4.3. Holes shall be backfilled with

selected earth or stable materials in layers not
exceeding 100 mm thickness and each layer shall be
thoroughly tamped and rammed. When backfilling
and tamping arc completed, the posts or anchors
shall be held securely in place.
810.4.4. Post holes that are drilled in rock
and holes for anchor posts shall be backfilled with
concrete.
810.4.5. Posts for metal beam guardrails on

bridges shall be bolted to the structure as detailed on
the plans. The anchor bolts shall be set to proper
location and elevation with templates and carefully
checked.
810.5. Erection
810.5.1. All guardrail anchors shall be set

and attachments made and placed as indicated on the
plans or as directed by the Engineer.
Page 729 of 1427

810.5.2. All bolts or clips used for fastening
the guardrail or fittings to the posts shall be drawn
up tightly. Each bolt shall have sufficient length to
extend at least 6 mm through and beyond, the full
nut, except where such extensions might interfere
with or
Page 730 of 1427

endanger traffic in which case the bolts shall be cut
off flush with the nut.
810.5.3. All railings shall be erected, drawn

and adjusted so that the longitudinal tension will be
uniform throughout the entire length of the rail.
810.6. Tolerance
The posts shall be vertical with a tolerance

not exceeding 6 mm in a length of 3 metre. The
railing barrier shall be erected true to line and grade.
810.7.1. Metal beam railing barriers will be

measured by linear metre of completed length as per
plans and accepted in place. Terminals/ anchors of
various types shall be paid for by numbers.
810.7.2. No measurement for payment shall

be made for projections or anchors beyond the end
posts except as noted above. Furnishing and placing
anchor bolts and/or devices for guard rail posts
on bridges shall be considered incidental to the
construction and the costs thereof shall be included
in the price for other items of construction.
810.7.3. No measurement for payment will

be made for excavation or backfilling performed in
connection with this construction.
Page 731 of 1427

810.8. Rate
The Contract unit rate shall include full

compensation for furnishing of labour, materials,
tools, equipments and incidental costs necessary for
doing all the work involved in constructing the metal
beam railing barrier complete in place in all respects
as per these Specifications.
811. ROAD TRAFFIC SIGNALS
811.1. General
The traffic signal, its configuration, size and

location shall be in accordance with IRC: 93 and IS:
7537 and as shown in the drawings or as directed by
the Engineer. Prior to installation of signals, the
Contractor shall submit to the Engineer, for
approval, detailed proposals showing the signal type,
sizes, paint and structural details of the signal posts
including control system.
811.2. The traffic signals shall have a

complete electronic mechanism for controlling the
operation of traffic with an auxiliary manual
controller. The time plan of signals shall be as per
drawing and shall be modified as directed by the
Engineer.
811.3. Materials
The various materials and fabrication thereof shall
Page 732 of 1427

conform to the following:
Page 733 of 1427

811.3.1. Signal foundation: The signal
foundations shall be constructed as per
Specifications given in Clause 13 of IRC : 93 or as
shown in the drawings.
811.3.2. Constructional requirements:

The constructional requirements for post, signal
head assembly, signal head, optical system, lamp and
holder, visor, post, supports for overhead mounted
signals, equipment housing, locks, inter-connecting
cables, earthing, mains termination, controller
electrical components, etc., shall conform to IS:
7537 unless otherwise stated in IRC: 93. The post
shall be painted and protected as per Clause 3.7.
of IS: 7537.
811.3.3. Optical requirements: The shape

of all signal lenses shall be circular and shall be of
specified colour and size and as shown in the
drawing. Quality of lenses, arrangement of lenses,
illuminations, visibility and shielding of signals
shall be as per relevant Clauses of IRC : 93 and
IS:7537.
811.4. Tests
Tests shall be carried out on all components

of traffic signal including tests on complete system
for its performance as per relevant Clauses of IRC :
93 and IS: 7537.
Page 734 of 1427

811.5. Maintenance of Traffic Signals
It shall be the responsibility of the

Contractor to provide for maintenance of the signal
section system throughout the warranty period for at
least five (5) years after installation and as per
Clause 18 of IRC : 93.
The measurement for traffic signalisation

system shall be by unit for complete work as
specified and as per drawing for complete road
junction.
811.7. Rate
The Contract unit rate for the traffic

signalisation system as a whole shall be payment in
full compensation for furnishing all labour,
materials, tools, equipment for preparing, supplying,
fixing at site, testing and maintenance throughout
warranty period and all other incidental costs
necessary to complete and maintain the work to
these Specifications.
Page 735 of 1427

Quality Control for Road Works
900
Page 736 of 1427

901. GENERAL
901.1. All materials to be used, all methods

adopted and all works performed shall be strictly in
accordance with the requirements of these
specifications. The Contractor shall set up a field
laboratory at locations approved by the Engineer and
equip the same with adequate equipment and
personnel in order to carry out all required tests and
Quality Control work piper Specifications and/or as
directed by the Engineer. The internal layout of the
laboratory shall be as per Clause 121 and/or as
directed by the Engineer. The list of equipment and
the facilities to be provided shall be got approved
from the Engineer in advance.
901.2. The Contractor’s laboratory should be

manned by a qualified Materials Engineer/Civil
Engineer assisted by experienced technicians, and
the set-up should be got approved by the Engineer.
901.3. The Contractor shall carry out quality

control tests on the materials and work to the
frequency stipulated in subsequent paragraphs. In me
absence of clear indications about method and or
frequency of tests for any item, the instructions of
the Engineer shall be followed.
901.4. For satisfying himself about the

quality of the materials and work, quality control
tests will also be conducted by the Engineer (by
himself, by his Quality Control Units or by any other
Page 737 of 1427

agencies deemed fit by him), generally to the
frequency set forth here in under. Additional tests
may also, fee conducted where, in the opinion of the
Engineer, need for such tests exists.
901.5. The Contractor shall provide

necessary co-operation and assistance in obtaining
the samples for tests and carrying out the field tests
required by the Engineer from time to time. This
may include provision of labour, attendants,
assistance in packing and despatching and any other
assistance considered necessary in connection with
the tests.
901.6. For the work of embankment,
subgrade and pavement, construction of subsequent
layer of same or other material over the finished
layer shall lie done after obtaining permission from
the Engineer. Similar permission from the Engineer
shall be obtained in respect of all other items of
works prior to proceeding with the next stage of
construction.
901.7. The Contractor shall carry out

modifications in the procedure of work, if found
necessary, as directed by the Engineer during
inspection. Works falling short of quality shall be
rectified/redone by the Contractor at Ws own cost,
and defective work shall also be removed from the
site of works by the Contractor at his own cost.
901.8. The cost of laboratory building

including services, essential supplies like water,
Page 738 of 1427

electricity, sanitary services and their maintenance
and cost of all equipment, tools, materials, labour
and incidentals to perform tests and other operations
of quality control according to the Specification
requirements shall be deemed to be incidental to the
work and no extra payment shall be made for the
same. If, however, there is a sep; rate item in the Bill
of Quantities for setting up of a laboratory and
installing testing equipment, such work shall be paid
for separately.
901.9. For testing of samples of soils/soil

mixes, granular materials, and mixes, bituminous
materials and mixes, aggregates, cores etc., samples
in the required quantity and form shall be supplied
to the Engineer by the Contractor at his own cost.
901.10. For cement, bitumen, mild steel,

and similar other materials where essential tests are
to be carried out at the manufacturer’s plants or at
laboratories other than the site laboratory, the cost of
samples, sampling, testing and furnishing of test
certificates shall be borne by the Contractor. He shall
also” furnish the test certificates to the Engineer.
901.11. For testing of cement concrete at site

during construction, arrangements for supply of
samples, sampling, testing and supply of test results
shall be made by the Contractor as per the frequency
and number of tests specified in the Handbook of
Quality Control for Construction of Roads and
Runways (IRC :SP 11) and relevant IS Codes or
Page 739 of 1427

relevant clauses of these Specifications, the cost of
which shall be borne by the Contractor.
901.12. The method of sampling and testing

of materials shall be as required by the “Handbook
of Quality Control for Construction of Roads and
Runways” (IRC : SP: 11), and these MOST
Specifications. Where they are contradicting, the
provision in these Specifications shall be followed,
Where they are silent, sound engineering practices
shall be adopted. The sampling and testing procedure
to be used shall be as approved by the Engineer and
his decision shall be final and binding on the
Contractor.
901.13. The materials for embankment

construction shall be got approved from the
Engineer. The responsibility for arranging and
obtaining the land for borrowing or exploitation in
any other way shall rest with the Contractor who
shall ensure smooth and uninterrupted supply of
materials in the required quantity during the
construction period.
Similarly, the supply of aggregates for
construction of road pavement shall be from quarries
approved by the Engineer. Responsibility for
arranging uninterrupted supply of materials from the
source shall be that of the Contractor.
901.14. Defective Materials
All materials which the Engineer/his
Page 740 of 1427

representative has determined as not conforming to
the requirements of the Contract shall be rejected
whether in place or not; they shall be removed
immediately from the site as directed. Materials,
which have been subsequently corrected, shall not be
used in the work unless approval is accorded in
writing by the Engineer. Upon failure of the
Contractor to comply with any order of-’he
Engineer/his representative, given under this Clause,
the Engineer/his representative shall have authority
to cause the removal of rejected material and to
deduct the removal cost thereof from any payments
due to the Contractor.
901.15. Imported Materials
At the time of submission of tenders, the

Contractor shall furnish a list of materials/finished
products manufactured, produced or fabricated
outside India which he proposes to use in the work.
The Contractor shall not be entitled to extension of
time for acts or events occurring outside India and it
shall be the Contractor’s responsibility to make
timely delivery to the job site of all such materials
obtained from outside India.
The materials imported from outside India

shall conform to the relevant Specifications of the
Contract In case where materials/ finished products
are not covered by the Specifications in the Contract,
the details of Specifications proposed to be followed
and the testing procedure as well as laboratories/’
Page 741 of 1427

establishments where tests are to be carried out shall
be specifically brought out and agreed to in the
Contract.
The Contractor shall famish to the Engineer a

certificate of compliance of the tests carried out. In
addition, certified mill test reports clearly identified
to the lot of materials shall be furnished at the
Contractor’s cost.
902. CONTROL OF ALIGNMENT, LEVEL

AND SURFACE REGULARITY
902.1. General
All works performed shall conform to the

lines, grades, cross sections and dimensions shown
on the drawings or as directed by the Engineer,
subject to the permitted tolerances described herein-
after:
902.2. Horizontal Alignment
Horizontal alignments shall be reckoned with

respect to the centre line of the carriageway as
shown on the drawings. The edges of the
carriageway as constructed shall be correct within a
tolerance of± 10 mm there from. The corresponding
tolerance for edges of the roadway and lower layers
of pavement shall be ± 25 mm.
902.3. Surface Levels
Page 742 of 1427

The levels of the subgrade and different
pavement courses as constructed, shall not vary from
those calculated with reference to the longitudinal
and cross-profile of the road shown on the drawings
or as directed by the Engineer beyond the tolerances
mentioned in Table 900-1.
TABLE 900-T. TOLERANCES IN SURFACE

LEVELS
1. Subgrade + 20 mm
- 25mm
2. Sub-base + 10 mm -20mm
(a) Flexible pavement + 6 mm
(b) Concrete -10mm
pavement
[Dry clean concrete
or Rolled concrete]
3. Base-course for flexible +6 mm

pavement -6mm
(a) Bituminous course +10mm
(b) Other than -10mm
bituminous + 15 mm
(i) Machine laid -15 mm
(ii) Manually laid
4. Wearing course for + 6 mm

flexible pavement - 6mm
(a) Machine laid + 10mm
Page 743 of 1427

(b) Manually kid - 10mm
5. Cement concrete + 5 mm
pavement -6mm*
* This may not exceed - 8 mm at 0 - 30 cm from

the edges.
Provided, however, that the negative
tolerance for wearing course shall not be permitted
in conjunction with the positive tolerance for base
course, if the thickness of the former is thereby
reduced by more than 6mm for flexible pavements
and 5 mm for concrete pavements.
For checking compliance with the above

requirement for subgrade, sub-base and base courses,
measurements of the surface levels shall be taken on
, a grid of points placed at 6.25 m longitudinally and
3.5 m transversely. For any 10 consecutive
measurements taken longitudinally or transversely,
not more than one measurement shall be permitted to
exceed the tolerance as above, this one measurement
being not in excess of 5 mm above the permitted
tolerance.
For checking the. compliance with the above
requirement for bituminous wearing courses and
concrete pavements, measurements of the surface
levels shall be taken on a grid of points spaced at
6.25 m along the length and at 0.5 m from the edges
and at the centre of the pavement. In any length of
pavement, compliance shall be deemed to be met for
the final road surface, only if the tolerance given
Page 744 of 1427

above is satisfied for any point on the surface.
902.4. Surface Regularity of Pavement

Courses
The longitudinal profile shall be checked

with a 3 metre long straight edge/moving straight-
edge as desired by the Engineer at the middle of each
traffic lane along a line parallel to the centre line of
the road.
The maximum permitted number of surface
irregularities shall be as per Table 900-2.
TABLE 900-2. MAXIMUM PERMITTED NUMBER

OF SURFACE IRREGULARITIES
Surfaces of Surfaces
carriageways paved areas and
shoulders base and
courses
Irregularity 4 mm 7 mm 4 mm
Length(m) 300 75 300 75 300 7
National Highways/
Expressways 20 9 2 1 40 1
Roads of lower
category* 40 18 4 2 60 27
•Category of each section of road as
described in the Contract
The maximum allowable difference between

the road surface and underside of a 3 m straight-edge
Page 745 of 1427

when placed parallel with, or at right angles to the
centre line of the road at points decided by the
Engineer shall be:
for pavement surface (bituminous and

cement concrete) 3 mm
for bituminous base courses

6 mm
for granular sub-base/ base courses

8 mm
for sub-bases under concrete pavements

10 mm
902.5. Rectification
Where the surface regularity of subgrade and

the various pavement courses fall outside the
specified tolerances, the Contractor shall be liable to
rectify these in the manner described below and to
the satisfaction of the Engineer.
(1) Subgrade: Where the surface is high, it

shall be trimmed and suitably
compacted. Where the same is low, the
deficiency shall be corrected by
scarifying the lower layer and adding
fresh material and recompacting to the
required density. The degree of
Page 746 of 1427

compaction and the type of material to
be used shall conform to the
(ii) Granular Sub-base: Same as at (i)

above, except that the degree of
compaction and the type of material to
be used shall conform to the
(iii) Lime/Cement Stabilized Soil Sub-

base: For lime/cement treated materials
where the surface is high, the same shall
be suitably trimmed while taking care
that the material below is not disturbed
due to this operation. However, where
the surface is low, the same shall be
corrected as described herein below.
For cement treated material, when the
time elapsed between detection of
irregularity and the time of mixing of the
material is less than 2 hours, the surface
shall be scarified to a depth of 50 mm
supplemented with freshly mixed
materials as necessary and recompacted
to the relevant specification. When this
time is more than 2 hours, the full depth
of the layer shall be removed from the
pavement and replaced with fresh
material to Specification. This shall also
apply to lime treated material except that
the time criterion shall be 3 hours
Page 747 of 1427

instead of 2 hours.
(iv) Water Bound Macadam/Wet Mix

Macadam Sub-base/Base: Where the
surface is high or low, the top 75 mm
shall be scarified, reshaped with added
material as necessary and recompacted
to Clause 404. This shall also apply to
wet mix macadam to Clause 406.
(v) Bituminous Constructions: For

bituminous construction oilier than
wearing course, where the surface is low,
the deficiency shall be corrected by
adding fresh material over a suitable tack
coat if needed and recompacting to
specifications. Where the surface is high,
the full depth of the layer shall be
removed and replaced with fresh material
and compacted to specifications.
For wearing course, where the surface is

high or low, the full depth of the layer
shall be removed and replaced with fresh
material and compacted to
specifications. In all cases where the
removal and replacement of a
bituminous layer is involved, the area
treated shall not be less than 5 m in
length and not less than 3-5 m in width.
(vi) Dry Lean Concrete Sub-base/Rolled
Page 748 of 1427

Cement Concrete: The defective length
of the course shall be removed to full
depth and replaced with material
conforming to Clauses 601 or 603, as
applicable. The area treated shall be at
least 3 m long, not less than 1 lane wide
and extend to the full depth. Before
relaying the course, the disturbed
subgrade or layer below shall be
corrected by levelling, watering and
compacting.
(vii) Cement concrete pavement: The

defective areas having surface
irregularity exceeding 3 mm but not
greater than 6 mm may be rectified by
bump cutting or scrabbling or grinding
using approved equipment. When
required by the Engineer, areas which
have been reduced in level by the above
operation(s) shall be retextured in an
approved manner either by cutting
grooves ( 5 mm deep) or roughening
the surface by hacking the surface. If
high areas in excess 6 mm or low areas
in excess of 3 mm occur, exceeding the
permitted numbers and if the Contractor
cannot rectify, the slab shall be
demolished and reconstructed at the
Contractor’s expense and in no case the
area removed shall be lest than the full
width of the lane in which the
Page 749 of 1427

irregularity occurs and full length of the
slab.
If deemed necessary by the Engineer,

any section of the slab which deviates
from the specified levels and tolerances
shall be demolished and reconstructed
at the Contractor’s expense.
903. QUALITY CONTROL TESTS

DURING CONSTRUCTION
903.1. General
The materials supplied and the works carried

out by the Contractor shall conform to the
specifications prescribed in the preceding Clauses.
For ensuring the requisite quality of

construction, the materials and works shall be
subjected to quality control tests, as described
hereinafter. The testing frequencies set forth are the
desirable minimum and the Engineer shall have the
full authority to carry out additional tests as
frequently as he may deem necessary, to satisfy
himself that the materials and works comply with the
appropriate specifications. However, the number of
tests recommended in Tables 900-3 and 900-4 may
be reduced at the discretion of the Engineer if it is
felt that consistency in the quality of materials can
still be maintained with the reduced number of tests.
Page 750 of 1427

Test procedures for the various quality
control tests are indicated in the respective Sections
of these Specifications or for certain tests within this
Section. Where no specific testing procedure is
mentioned, the tests shall be carried out as per the
prevalent accepted engineering practice to the
directions of the Engineer.
903.2. Tests on Earthwork for

Embankment, Subgrade Construction and Cut
Formation
903.2.1. Borrow material : Grid the borrow

area at 25 m c/c (or closer, if the variability is high)
to full depth of proposed working. These pits should
be logged and plotted for proper identification of
suitable sources of material. The following tests on
representative samples shall be carried out:
(a) Sand Content [IS: 2720 (Part-4)] : 2

tests per 3000 cubic metres of soil.
(b) Plasticity Test[IS:2720 (Part-5)] : Each

type to be tested, 2 tests per 3000 cub.
metres of soil.
(c) Density Test [IS:2720 (Part-8)]: Each

soil type to be tested. 2 tests per 3000
cubic metres of soil.
(d) Deleterious Content Test [1S:2720

(Part-27)] : As and when required by the
Page 751 of 1427

Engineer.
(e) Moisture Content Test [IS :2720 (Part-

2) ]: One test for every 250 cubic metres
of soil.
(f) CBR Test on materials to be incorporated

in the subgrade on soaked/unsoaked
samples [IS : 2720 (Part-16)]: One CBR
test for every 3000 cu. m. at least or
closer as and when required by the
Engineer.
903.2.2. Compaction Control: Control shall

be exercised on each layer by taking at least one
measurement of density for each 1000 square metres
of compacted area, or closer as required to yield the
minimum number of lest results for evaluating a
day’s work on statistical basis. The determination of
density shall be in accordance with IS: 2720 (Part-
28). Test locations shall be chosen only through
random sampling techniques. Control shall not be
based on the result of any one test but on the mean
value of a set of 5-10 density determinations. The
number of tests in one set of measurements shall be
6 (if non-destructive tests are carried out, the number
of tests shall be doubled) as long as it is felt that
sufficient control over borrow material and the
method of compaction is being exercised. If
considerable variations are observed between
individual density results, the minimum number of
tests in one set of measurement shall be increased to
Page 752 of 1427

10. The acceptance criteria shall be subject to the
condition that the mean density is not less than the
specified density plus:
 1.65 
1.65  0.5 
times the standard deviation
 ( No.ofSamples) 
However, for earthwork in shoulders

(earthen) and in the subgrade, at least one density
measurement shall be taken for every 500 square
metres for the compacted area provided further that
the number of tests in each set of measurements shall
be at least 10. In other respects, the control shall be
similar to that described earlier.
903.2.3. Cut formation : Tests for the

density requirements of cut formation shall be
carried out in accordance with Clause 903.2.2.
903.3. Tests on Sub-bases and Bases

(excluding bitumen bound bases)
The tests and their frequencies for the

different types of bases and sub-bases shall be as
given in Table 900-3. The evaluation of density
results and acceptance criteria for compaction
control shall be on lines similar to those set out in
Clause 903.2.2.
903.3.1. Acceptance criteria: The
Page 753 of 1427

acceptance criteria for tests on the strength of
cement/lime stabilised soil and distribution of
stabiliser content shall be subject to the condition
that the mean value is not less than the specified
value plus:
 1.65 
1.65  0.5 
 ( No.ofSamples) 
TABLE 900-3. CONTROL TESTS AND THEIR

MINIMUM FREQUENCY FOR
SUB-BASES AND BASES
(EXCLUDING BITUMEN BOUND
BASES)
SL. Type of Test Frequency

No. Construction (min.)
1. Granular (i) Gradation One test per
(ii) Atterberg limits 200 m3 One
(iii) Moisture test per 200
content prior to m3 One lest
compaction per 250m2
(iv) Density of
compacted layer One test per
(v) Deleterious 500 m2 As
constituents required
(vi) C.B.R. As required
2. Lime/Cemen (i) Quality of One test for

t Stabilised lime/ cement each
Soil Sub- consignment
Page 754 of 1427

base subject to a
minimum of
one test per
(ii) Lime/Cement 5 tonnes
content
Regularly,
through
(iii) Degree of procedural
pulverization checks
Periodically
as
(iv) CBR or considered
Unconfined necessary
Compressive
Strength test As required
on a set of 3
specimens
(v) Moisture
content prior One test per
to compaction 250 sq.m.
(vi) Density of
compacted layer One test per
500 m2
(vii) Deleterious
constituents As required
3 Water (i) Aggregate One test per

Bound Impact Value 200 m3
Macadam aggregate
Page 755 of 1427

(ii) Grading One test per
100 m3
(iii) Flakiness
Index and One test per
Elongation 200 m3 of
index Aggregate
(iv) Atterberg One lest per

limits of 25 m3 of
binding binding
material material
(v) Atterberg One test per

limits of 100 cubic
portion of metre of
aggregate aggregate
passing 425
micron sieve
4. Wet Mix (i) Aggregate One test per

Macadam Impact value 200 m3 of
aggregate
(ii) Grading One test per

100 m3 of
(iii) Flakiness and aggregate
Elongination One test per
Index 200 m3 of
aggregate
(iv) Atterberg
limits of One test per
Page 756 of 1427

portion of 100 m3 of
aggregate aggregate
passing 425
micron sieve One test per
(v) Density of 500 m2
compacted
layer
903.4. Tests on Bituminous Construction
903.4.1. Tests and frequency : The tests

and their minimum frequencies for the different
types of bituminous works shall be as given in Table
900-4”. The Engineer may direct additional testing
as required.
903.4.2. Acceptance criteria : The

acceptance criteria for tests on density and Marshall
stability shall be subject to the condition that the
mean value is not less than the specified value plus :
 1.65 
1.65  0.5 
 ( No.ofSamples ) 
TABLE 900-4. CONTROL TESTS FOR

BITUMINOUS WORKS ANS THEIR
MINIMUM FREQUENCY
SL. Type of Test Frequency
No. Construction (min.)
1. Prime (i) Quality of binder Number of
Page 757 of 1427

Coat/Tack samples per
Coat/ Fog Tot and tests
Spray as per IS: 73,
IS:217 and
(ii) Binder temperature IS:8887 as
for application applicable.
(iii) Rate of spread of
Binder At regular
close intervals
One test per

500m2 and
not less than
two tests per
day
2. Seal (i) Quality of Binder Same as

Coat/Surface mentioned
Dressing under Serial
Stabilised Soil No. 1
Sub-base (ii) Aggregate Impact
Value/Los Angeles
Abrasion Value One test per
50 m3of
(iii) Flakiness Index and aggregate
Elongation Index
-do-
(iv) Stripping value of
aggregates
(Immersion Trey Initially one
Test) set of 3
representative
Page 758 of 1427

specimens for
each source
of supply.
Subsequently
when
(v) Water absorption of warranted by
aggregates changes in
the quality of
(vi) Water sensitivity of aggregates
mix
-do-
Initially one
set of 3
representative
specimens for
each source
(vii) Grading of of supply.
aggregates Subsequently
when
warranted by
(viii) Soundness changes in
(Magnesium and the quality of
Sodium Sulphate) aggregates (if
required)
One test per

25 m3 of
aggregate
(ix) Polished stone value
Page 759 of 1427

Initially, one
(x) Temperature of determination
binder at application by each
method for
(xi) Rate of spread of each source
materials of supply,
then as
warranted by
change in the
(xii) Percentage of quality of the
fractured faces aggregates.
As required
At regular
close
intervals
One test per

500 m2 of
work, and,
not less than
two tests per
day
When gravel
is used, one
test per 50m3
of aggregate
3. Open-graded (i) Quality of binder Same as
Page 760 of 1427

Premix mentioned
Surfacing/ under Serial
Close-graded (ii) Aggregate Impact No. 1
Premix Value/Los Angeles
Surfacing Abrasion Value Same as
mentioned
(iii) Flakiness Index and under Serial
Elongation Index No.2
(iv) Stripping value -do-
(v) Water absorption of Same as

aggregates mentioned
under Serial
(vi) Water sensitivity of No.2
mix
Same as
mentioned
(vii) Grading of under Serial
aggregates No.2
Same as
(viii) Soundness mentioned
(Magnesium and under Serial
Sodium Sulphate) No. 2
(ix) Polished stone value Same as

mentioned
(x) Temperature of under Serial
binder at application No.2
Page 761 of 1427

(xi) Binder content Same as
mentioned
under Serial
No.2
(xii) Rate of spread of
mixed material As required
(xiii) Percentage of At regular

fractured faces close
intervals
One test per

500m3 and
not less than
two tests per
day
Regular
control
through
checks of
layer
thickness
Same as
mentioned
under Serial
No.2
4. Bituminous (i) Quality of binder Same as

Macadam mentioned
Page 762 of 1427

under Serial
(ii) Aggregate Impact No I
Value/Los Angeles
Abrasion Value Same as
mentioned
Elongation Index No 2
(iv) Stripping Value Same as

mentioned
under Serial
(v) Water sensitivity of No .2
mix
Same as
(vi) Grading of mentioned
aggregates under Serial
No .2
-do-
Two tests per

(vii) Water absorption of day per plant
aggregates both on the
individual
(viii) Soundness constituents
(Magnesium and and mixed
Sodium Sulphate) aggregates
from the
(ix) Percentage of dryer
fractured faces
Same as in
Serial No 2
Page 763 of 1427

(x) Binder content and
aggregate grading
Same as
mentioned
(xi) Control of under Serial
temperature of No.2
binder and aggregate
for mixing and of Same as
the mix at the time mentioned
of laying and rolling under Serial
No.2
(xii) Rate of spread of
mixed material Periodic,
subject to
(xiii) Density of minimum of
compacted layer two tests per
day per plant
At regular
close
intervals
Regular
control
through
checks of
layer
thickness
One test per

250m2 of
Page 764 of 1427

area layer
5. Bituminous (i) Quality of binder Same as
Penetration mentioned
Macadam/Built- under Serial
up Spray-Grout (ii) Aggregate Impact No. 1
Value/Los Angeles
Abrasion Value One test per
250 m3 of
(iii) Flakiness Index and aggregate
Elongation Index
-do-
(iv) Stripping value
Same as
(v) Water absorption of mentioned
aggregates under Serial
No. 2
(vi) Water sensitivity of
mix Same as
Serial No. 2
(vii) Aggregates grading
Same as
(viii) Soundness Serial No.2
(Magnesium and
Sodium Sulphate) One test per
100 m3 of
(ix) Percentage of aggregate
fractured faces
Same as
mentioned
(x) Temperature of under Serial
Page 765 of 1427

binder at application No. 2
(xi) Rate of spread of Same as

binder mentioned
under Serial
No. 2
At regular
close
intervals
Same as
mentioned
under Serial
No. 2
6. Dense (i) Quality of binder Same as
Bituminous mentioned
Macadam/ Semi under Serial
Dense (ii) Aggregate Impact No. 1
Bituminous Value/Los Angeles
Concrete/ Abrasion Value Same as
Bituminous mentioned
Concrete under Serial
(iii) Flakiness Index and No. 2
Elongation Index
(iv) Stripping value -do-
(v) Soundness Same as

(Magnesium and mentioned
Sodium Sulphate) under Serial
Page 766 of 1427

No. 2
(vi) Water absorption of
aggregates Same as
mentioned
(vii) Sand equivalent test under Serial
No. 2
(viii) Plasiticity Index
As in Serial
(ix) Polished stone value No. 2
As required
(x) Percentage of As required

fractured faces
As required,
for Semi
(xi) Mix grading Dense
Bituminous
Concrete/
Bituminous
Concrete
Same as
mentioned
(xii) Stability of Mix under Serial
No. 2
One set of
tests on
individual
constituents
Page 767 of 1427

and mixed
aggregate
from the
dryer of each
(xiii) Water sensitivity of 400 tonnes of
mix (Retained mix subject
Tensile Strength) to a
minimum of
(xiv) Swell test on the tests per plant
mix per day.
For each 400

(xv) Control of tonnes of mix
temperature of produced, a
binder in boiler, set of 3
aggregate in the Marshall
dryer and mix at the specimens to
time of laying and be prepared
rolling and tested for
stability, flow
(xvi) Control of binder value,
content and grading density, and
of the mix void content
subject to a
minimum of
two sets
(xvii) Rate of spread of being tested
mixed material per plant per
day.
Same as
(xviii) Density of mentioned
Page 768 of 1427

compacted layer under Serial
No. 2
As required
for the
Bituminous
Concrete
At regular
close
intervals
One test for

each 400
tonnes of mix
subject to a
minimum of
two tests per
day per plant.
Regular
control
through
checks on the
weight of
mixed
material and
layer
thickness
Page 769 of 1427

One test per
250 m2 area
7. Mastic Asphalt (i) Quality of binder Same as

mentioned
under Serial
(ii) Aggregate Impact No. 1
Value/Los Angeles
Abrasion Value Same as
mentioned
Elongation Index No. 2
(iv) Stripping Value -do-
(v) Water sensitivity of

mix -do-
(vi) Grading of -do-

aggregates
Two tests per
day per plant
both on the
individual
constituents
(vii) Water absorption of and mixed
aggregates aggregates
from the
(viii) Soundness dryer
(Magnesium and
Sodium Sulphate) Same as in
Page 770 of 1427

Serial No. 2
(ix) Percentage of
fractured faces
Same as
mentioned
(x) Binder content and under Serial
aggregate grading No. 2
Same as
(xi) Control of mentioned
temperature, of under Serial
binder and aggregate No. 2
for mixing and of
the mix at the time Periodic,
of laying and subject to
rolling. minimum of
two tests per
(xii) Rate of spread of day per plant
mixed material
At regular
(xiii) Hardness number close
intervals.
Regular
control
through
checks of
layer
thickness
Page 771 of 1427

One test for
each 400
tonnes of mix
subjects to a
minimum of
two tests per
day
8. Slurry Seal (i) Quality of binder Same as

mentioned
under Serial
(ii) Film stripping test No. 1.
Initially one
set of 3
representative
specimens for
each source
of supply,
then as
warranted by
changes in
the quality of
aggregates
Page 772 of 1427

9. Recycled (i) Binder content and Minimum of
Material aggregate grading one test per
25 m3 of
recycled
(ii) Recovered binder material
penetration
Minimum of
one test per
50m3 of
(iii) Mix stability recycled
(Remix/ Repave) material
For each 400

tonnes of mix
recycled, a
set of 3
Marshall
specimens to
be prepared
and tested for
stability,
flow, density
and void
content,
subject to a
minimum of
two sets of
tests per day
10. Cold Mix (i) Quality of binder Same as

mentioned
under Serial
Page 773 of 1427

(ii) Aggregate Impact No. 1
Value/Los
Angeles Abrasion Same as
Value mentioned
under Serial
(iii) Flakiness Index No.2
and Elongation
Index -do-
(iv) Stripping value

-do-
(v) Water sensitivity
of mix -do-
(vi) Grading Two tests per

aggregates day per plant
both on the
individual
constituents
and mixed
aggregates
(vii) Percentage from the
minimum dryer
coating
Two tests
per day per
(viii) Water plant
absorption of
Page 774 of 1427

aggregates Same as in
Serial No. 2
(ix) Soundness
(Magnesium
and Sodium Same as
Sulphate) mentioned
under Serial
No.2
(x) Percentage of
fractured faces
When gravel
is used, one
test per 50m3
(xi) Binder content of aggregate
and aggregate
grading Periodic,
subject to
minimum of
(xii) Mix Stability two tests per
day per plant
For each 400

tonnes of mix
produced,
one set of 3
Marshall
specimens to
be prepared
and tested for
stability,
flow, density
and void
Page 775 of 1427

content,
subject to a
minimum of
two sets of
tests per plant
per day
11. Sand Asphalt (i) Quality of binder Same as
Base Course mentioned
under Serial
(ii) Los Angeles No. 1
Abrasion Value
Same as
mentioned
(iii) Send equivalent test under Serial
No. 2
(iv) Plasiticity Index
As required
(v) Mix grading
As required
One set of
tests on
individual
constituents
and mixed
aggregate
(vi) Stability of Mix from the
dryer for each
400 tonnes of
mix subject
to a
minimum of
Page 776 of 1427

two tests per
plant per day
For each 400

(vii) Control of tonnes of mix
temperature of produced, a
binder in boiler, set of 3
aggregate in the Marshall
dryer and mix at the specimens to
time of laying and be prepared
rolling and tested for
stability, flow
(viii) Control of binder value, density
content and grading and void
of the mix content
subject to a
minimum of
two sets
(ix) Rate of spread of being tested
mixed material per plant per
day
At regular
close
(x) Density of intervals
compacted layer
One test for

each 400
tonnes of mix
subjects to a
Page 777 of 1427

minimum of
two tests per
day per plant
Regular
control and
through
checks on the
weight of
mixed
material and
layer
thickness
One test per

250 m2 area
12. Modified (i) Softening Point Initially on
Binder submission
thereafter
daily if site
blended,
(ii) Penetration at 25oC weekly if
and 4oC pre-blended
(iii) Elastic Recovery -do-
(iv) Ductility -do-
(v) Flash Point -do-
(vi) Fraass Breaking -do-
Page 778 of 1427

(vii) Viscosity at 150oC Initially on
submission
(viii) Thin film oven test,
penetration, -do-
softening point,
elastic recovery of -do-
residue, loss on
heating
13. Geotextiles The requirement of Clause
704.3.1 of the Ministry’s
Specification for Road and
Bridge Works (third
revision) shall apply
903.5. Quality Control Tests for Concrete Road

Construction
903.5.1. Dry lean concrete sub-base :
903.5.1.1. Sampling and testing of cubes:

Samples of dry lean concrete for making cubes shall
be taken from the uncompacted material from
different locations immediately before compaction at
the rate of 3 samples for each 1000 sq.m. or part
thereof laid each day. The sampling of mix shall be
done from the paving site.
Test cubes of 150mm size shall be made

immediately from each mix sample.
Cubes shall be made in accordance with the
methods described in IS:516 except that the cubes
shall be compacted by means of a vibratory hammer
Page 779 of 1427

with the moulds placed on a level and rigid base.
The vibrating hammer shall be electric or pneumatic
type fitted with a square or rectangular foot having
an area of between 7500 to 14000 sq.mm. The
compaction shall be uniformly applied for 60 ± 5
seconds with a downward force of between 300 N
and 400 N on to each of the three layers of the lean
concrete material placed into the mould. The surface
of each compacted layer shall be scarified before the
next layer is added to give key for. the next layer.
The final layer shall be finished flush with the top of
the cube mould.
The dry lean concrete cubes shall be cured in

accordance with IS:516.
903.5.1.2. In-situ density: The dry density of

the laid material shall be determined from three
density holes at locations equally spaced along a
diagonal that bisects each 2000 square metre or part
thereof laid each day and shall comply with the
requirements as per Clause 601.5.5.1. This rate of
testing may be increased at the discretion of the
Engineer in case of doubt or to determine the extent
of defective area in the event of non-compliance.
Density holes at random may be made to check the
density at edges.
903.5.1.3. Thickness: The average thickness

of the sub base layer as computed by the level data
of sub-base and subgrade or lower sub-base shall be
as per the thickness specified in the contract
Page 780 of 1427

drawings. The thickness at any single location shall
not be 10 mm less than the specified thickness. Such
areas shall be corrected as stated in Clause 601.5.5.5.
Areas which cannot be repaired should be replaced
over full width. The extent of deficient area should
be decided based on cores.
903.5.1.4. Frequency of quality control

tests: The frequency of quality control tests for
levels, alignment and materials shall be as in Table
900-6.
903.5.2. Pavement concrete
903.5.2.1. Sampling and testing of beam

and cube specimens: At least two beam and two
cube specimens, one each for 7 day and 28 day
strength testing shall be cast for ever 150 cu.m (or
part thereof) of, concrete placed during construction.
On each day’s work, not less than three pairs of
beams and cubes shall be made for each type of mix
from the concrete delivered to the paving plant. Each
pair shall be from a different delivery of concrete
and tested at a place to be designated by the
Engineer in accordance with the testing procedure as
outlined in Clause 602.3.3. Groups of four
consecutive results from single specimens tested at
28 days shall be used for assessing the strength for
compliance with the strength requirements. The
specimens shall be transported in an approved
manner to prevent sudden impact causing fractures
or damage to the specimen. The flexural strength test
Page 781 of 1427

results shall prevail over compressive strength tests
for compliance.
A quality control chart indicating the strength
values of individual specimens shall be maintained
for continuous quality assurance. Where the.
requirements are not met with, or where the quality
of the concrete or its compaction is suspect, the
actual strength of the concrete in the slab shall be
ascertained by carrying out tests on cores cut from
the hardened concrete at such locations. The cores
shall be cut at the rate of 2 cores for every 150 cu. m.
of concrete. The results of crushing strength tests on
these cores shall not be less than 0.8 times the
corresponding crushing strength of cubes, where the
height to diameter ratio of the core is two. Where
height to diameter ratio is varied, then the necessary
corrections shall be made in calculating the crushing
strength of cubes in the following manner.
The crushing strengths of cylinders with

height to diameter ratios between 1 and 2 may be
corrected to correspond to a standard cylinder of
height to diameter ratio of 2 by multiplying with the
correction factor obtained from the following
equation:
f = 0.11 n +0.78
where f = correction factor and
n = height to diameter ratio
Page 782 of 1427

The corrected test results shall be analysed
for conformity with the specification requirements
for cube samples. Where the core tests are
satisfactory, they shall have precedence for assessing
concrete quality over the results of moulded
specimens. The. diameter of cores shall not-be less
than 150 mm.
If, however, the tests on cores also confirm

that the concrete is not satisfying the strength
requirements, then the concrete corresponding to the
area from which the cores were cut should be
replaced, i.e., at least over an area extending between
two transverse joints where the defects could be
Isolated or over larger areas, if necessary, as
assessed by additional cores and their test results.
The equivalent flexural strength at 28 days shall be
estimated in accordance with Clause 602.3.3.2.
In order to ensure that the specified minimum

strength at 28 days is attained in 99 per cent of all
test beams, the mix shall be proportioned to give an
average strength at 28 days exceeding the specified
strength by 2.33 times the standard deviation
calculated first from the flexural strengths of test
beams made from the trial mix and subsequently
from the accumulating result of flexural strengths of
job control test beams.
The standard deviation shall be re-calculated

from the test results obtained after any change in the
source or quality of materials and the mix shall be
Page 783 of 1427

adjusted as necessary to comply with the
requirements.
An individual 28 day test strength below the

specified strength shall not be evidence for
condemnation of the concrete concerned if the
average 28 day strength of this beam plus the
preceding 5 and succeeding 4 beams exceeds the
specified strength by 2.33 times the standard
deviation and provided that there is no other
evidence that the concrete mix concerned is
substandard.
Beams shall be made each day in pairs at

intervals, each pair being from a different batch of
concrete. At the start of the work, and until such lime
as the Engineer may order a reduction in the number
of beams required, at least six pairs of beams and
cubes shall be made each day, one of each pair for
testing at 28 days for determination of ;he minimum
permissible flexural strength and the other for testing
at an early age for the Engineer to assess the quality
of the mix. When the first thirty number of 28-day
results arc available, and for so long as the Engineer
is satisfied with the quality of the mix, he may
reduce the number of beams and cubes required.
During the course of construction, when the

source of any material is to be changed, or if there is
any variation in the quality of the materials
furnished, additional tests and necessary adjustments
in the mix shall be made as required to obtain the
Page 784 of 1427

specified strength.
The flexural strengths obtained on beams

tested before 28 days shall be used in conjunction
with a correlation between them and the 28 day
flexural strengths to detect any deterioration in the
quality of the concrete being produced. Any such
deterioration shall be remedied without awaiting the
28 day strengths but the earlier strengths shall not
constitute sole evidence of non-compliance of the
concrete from which they were taken.
Concrete shall not comply with the
Specification when more than one lest beam in a
batch has a 28 day strength less than the specified
strength and the average 28 day flexural strength of
the batch of beams is less than the specified strength
plus 2.33 times the standard deviation of the batch.
Should the concrete fail to pass the

Specification for strength as described above, the
Contractor may, all at his own expense, elect to cut
cores from the suspect concrete as the Engineer shall
direct. From the relation between cube strength and
flexural strength, the core strength shall be converted
to flexural strength.
The equivalent flexural strength at 28 days

shall be the estimated insitu strength multiplied by
100 and divided by the age-strength relation
obtained from Table 900-5.
Any concrete that fails to meet the strength
Page 785 of 1427

specification shall be removed and replaced at
Contractor’s expense.
TABLE 900-5. AGE - STRENGTH RELATION

OF CONCRETE (RELATED TO 100 PER
CENT AT 28 DAYS)
DAYS 0 2 4
0 41.0 60.0 7
10 81.5 85.0 87.5 9
20 94.0 96.0 97.5 9
30 101.0 102.0 103.5 10
40 106.5 107.0 108.0 10
50 110.5 111.0 l!2.0 11
60 114.0 114.5 115.0 11
70 116.5 117.0 117.5 11
80 119.0 119.5 119.5 12
90 121.0 121.5 122.0 12
100 123.5 123.5 123.5 12
110 125.0 125.0 125.5 12
120 126.0 126.5 127.0 12
130 127.5 128.0 128.5 12
140 129.0 129.5 129.5 13
150 130.5 130.5 131.0 13
160 131.5 131.5 132.0 13
170 132.5 132.5 133.0 13
180 133.5 134.0 134.0 13
190 135.0 135.0 135.0 13
200 135.5 135.5 136.0 13
210 136.5 136.5 137.0 13
220 137.0 137.5 137.5 13
230 138.0 138.5 138.5 13
Page 786 of 1427

240 139.0 139.0 139.0 13
250 139.5 140.0 140.0 14
260 140.5 140.5 140.5 14
270 141.0 141.0 141.5 14
280 142.0 142.0 142.0 14
290 142.5 142.5 142.5 14
300 143.0 143.0 143.0 14
310 143.5 143.5 144.0 14
320 144.0 144.5 144.5 14
330 144.5 145.0 145.0 14
340 145.0 145.5 145.5 14
350 146.0 146.0 146.0 14
360 146.0 146.0 146.5 14
903.5.2.2. In-situ density : The density of

the compacted concrete shall be such that the total
air voids are not more than 3 per cent. The air voids
shall be derived from the difference between the
theoretical maximum dry density of the concrete
calculated from the specific gravities of the
constituents of the concrete mix and the average
value of three direct density measurements made on
cores at least 150 mm diameter. Three cores shall be
taken from trial lengths and in first two km length of
the pavement, while the slab is being constructed
during normal working. The proportions of the mix
and the vibratory effort imparted i.e the frequency
and magnitude of vibration shall be adjusted to
achieve the maximum density.
All cores taken for density measurement in

the trial section shall also be checked for thickness.
Page 787 of 1427

The same cores shall be made use of for determining
in-situ strength. In case of doubt, additional cores
may be ordered by the Engineer and taken at
locations decided by him to check the density of
concrete slab or the position of dowel/tie bars
without any compensation being paid for the same.
In calculating the density, allowance shall be

made for any steel in cores.
Cores removed from the main carriageway

shall be reinstated with compacted concrete with mix
proportions of 1 pan of portland cement: 2 parts of
fine aggregate : 2 parts of 10 mm nominal size single
sized coarse aggregate by weight. Before filling the
fine mix, the sides shall be hacked and cleaned with
water. Thereafter cement-sand slurry shall be applied
to the sides just prior to filling the concrete mix.
903.5.2 J. Thickness: Thickness shall be

controlled by taking levels as indicated in Clause
902.3. Thickness of the slab at any point checked as
mentioned above shall be within a tolerance of -5
mm to + 25 mm of the specified thickness as per
Drawing. Thickness deficiency more than 5 mm may
be accepted and paid for at a reduced rate given in
Clause 602.15.2. In no case, however, thickness
deficiency shall be more than 25 mm.
903.5.2.4. Summary or control tests : Table

900-6 gives a summary of frequency of testing of
pavement quality concrete.
Page 788 of 1427

TABLE 900-6 . FREQUENCY OF QUALITY
CONTROL TESTS FOR PAVING QUALITY
CONCRETE
1. Levels, alignment and

texture
(i) Level tolerance Clause 902.3
(ii) Width of pavement Clause 902.2

and position of
paving edges
Clauses 902.3 and
(iii) Pavement 903.5.2.3
thickness
To be checked @ one
(iv) Alignment of Joint per 400 m length
joints, widths, or a day’s work
depths of dowel whichever is more.
grooves
Once a day or one
day’s work, without
(v) Surface regularity disturbing the curing
both transversely operation.
and longitudinally
To be checked in trial
length as per Clause
(vi) Alignment of 602.105.2 and once on
dowel bars and every 2 km.
their accuracy/tie
bars Clause 602.9.8
Page 789 of 1427

(vii) Texture depth
2. Quality of Materials
and Concrete
Control tests for .
materials and concrete
shall be under
1. Cement Physical and IS: Once for each
chemical 269 source of
tests IS: supply and
455 occasionally
IS : when called
1489 for in case of
IS long/improper
:8112 storage.
IS : Besides, the
12269 Contractor
also will
submit daily
test data on
cement
released by
the
Manufacturer
1. Coarse and fine
aggregates
(i) Gradation IS: One lest for
2386 every day’s
(Pt. 1) work of each
fraction of
coarse
Page 790 of 1427

aggregate and
fine
aggregate,
initially; may
be relaxed
later at the
discretion of
the Engineer.
(ii) Deleteriou IS: -do-
s Constituents 2386
(Pt. 2)
(iii) Water IS: Regularly as

absorption 2386 required
(Pt. 3) subject to a
minimum of
one ten a day
for coarse
aggregate &
two tests a
day for fine
aggregate.
Thu data shall
be used for
correcting the
water demand
of the mi» on
daily basis.
3. Coarse Aggregate
(i) Los Angeles IS: Once for each
Abrasion value 2386 source of
of Aggregate (Pt. 4) supply and
Page 791 of 1427

Impact test subsequently
on monthly
IS: basis.
(ii) Soundness 2386
(Pt. 5) Before
approving the
aggregates
(iii) Alkali IS: and every
aggregate 2386 month
reactivity (Pt. 7) subsequently
-do-
(iv) Workability of
fresh concrete-
Slump Test
4. Water IS : Once for

Chemical Test 456 approval of
source of
supply,
subsequently
only in case
of doubt
5. Concrete
(i) Strength of IS : 2 cubes and 2
concrete 516 beams per
150 m3 or
part thereof
(one for 7day
and other for
28 day
Page 792 of 1427

strength) or
(ii) Core strength IS : minimum 6
on hardened 516 cubes and 6
concrete beams per
day’s work
whichever is
(iii) Workability of IS : more.
fresh 1199
As per the
requirement
of the
Engineer,
only in case
of doubt.
(iv) Thickness
determination One test per
each dumper
load at both
Batching
plant site and
(v) Thickness paving site
measurement initially when
for trial length work suns.
Subsequently
(vi) Verification of sampling may
level of string be done from
line in the case alternate
of slip form dumper.
paving and
steel forms in From the
the case of level data of
fixed form concrete
Page 793 of 1427

paving pavement
surface and
sub-base at
grid points of
5/ 6.25 m x
3.5 m
3 cores per
trial length.
String line or
steel forms
shall be
checked for
level at an
interval of
5.0m or 6.25
m. The level
tolerance
allowed shall
be ±2mm.
These shall be
got approved
1-2 hours
before the
com-
mencement of
the concreting
activity.
Page 794 of 1427

903.5.3. Rolled Concrete Base
903.5.3.1. Sampling and testing of beams

and cubes: Clause 903.5.2.1 shall apply
903.5.3.2. Thickness : Thickness shall be

controlled by taking levels as indicated in Clause
903.5.1.3.
903.5.3.3. In-situ density : The dry density

of the laid material shall be determined from three
density holes at locations equally spaced along a
diagonal that bisects each 2000 square metre or part
thereof laid each day and shall comply with the
requirements as per Clause 601.5.5.1. This rate of
testing may be increased at the discretion of the
Engineer in case of doubt or 40 determine the extent
of defective area in the event of non compliance.
Density holes at random may be made to check the
density at edges.
903.5.3.4. Summary of control tests : Table

900-6 gives the summary of tests for levels,
alignment and materials.
903.5.4. Summary of rate of sampling and
testing:
(i) Strength : 3 beams and 3 cubes for

each 100 sq. m. or part thereof laid each
day.
(ii) Density : 3 density holes for each
2000 sq.m. or part thereof laid each day.
Page 795 of 1427

(iii) Cores : Only when Engineer
instructs. They shall not be cut on
regular basis.
A relation between flexural strength and

compressive strength may be developed by
regression analysis using the available data. This
may be updated from time to time.
Page 796 of 1427

Materials for Structures
1000
Materials for Structures
Page 797 of 1427

1001. GENERAL
.Materials to be used in the work shall

conform to the specifications mentioned on the
drawings, the requirements laid down in this section
and specifications for relevant items of work covered
under these specifications.
If any material, not covered in these

specifications, is required to be used in the work, it
shall conform to relevant Indian Standards, if there
are any, or to the requirements specified by the
Engineer.
1002. SOURCES OF MATERIAL
The Contractor shall notify the Engineer of

his proposed sources of materials prior to delivery. If
it is found after trial that sources of supply
previously approved do not produce uniform and
satisfactory products, or if the product from any
other source proves unacceptable at any time, the
Contractor shall furnish acceptable material from
other sources at his own expense.
1003. BRICKS
Burnt clay bricks shall conform to the

requirements of IS: 1077, except that the minimum
compressive strength when tested flat shall not be
less than 8.4 MPa for individual bricks and 10.5
MPa for average of 5 specimens. They shall be free
Page 798 of 1427

from cracks and flaws and nodules of free lime. The
brick shall have smooth rectangular faces with sharp
corners and emit a clear ringing sound when struck.
The size may be according to local practice with a
tolerance of + 5 per cent.
1004. STONES
Stones shall be of the type specified. It shall

be hard, sound, free from cracks, decay and
weathering and shall be freshly quarried from an
approved quarry. Stone with round surface shall not
be used.
The stones, when immersed in water for 24

hours, shall not absorb water by more than 5 per cent
of their dry weight when tested in accordance with
IS: 1124.
The length of stones shall not exceed 3 times

its height nor shall they be less than twice its height
plus one joint. No stone shall be less in width than
the height and width on the base shall not be greater
than three-fourth of the thickness of the wall nor less
than 150 mm.
1005. CAST IRON
Cast iron shall conform to IS:210. The grade

number of the material shall not be less than 14.
1006. CEMENT
Page 799 of 1427

Cement to be used in the works shall be any
of the following types with the prior approval of the
Engineer :
a) Ordinary Portland Cement, 33 Grade,

conforming to JS:269.
b) Rapid Hardening Portland Cement,
conforming to IS:8041.
c) Ordinary Portland Cement, 43 Grade,
d) Ordinary Portland Cement, 53 Grade,
e) Sulphate Resistant Portland Cement,
Cement conforming to IS:269 shall be used

only after ensuring that the minimum required
design strength can be achieved without exceeding
the maximum permissible cement content of 540
kg/cu.m. of concrete.
Cement conforming to IS:8112 and 15:12269

may be used provided the minimum cement content
mentioned elsewhere from durability considerations
is not reduced. From strength considerations, these
cements shall be used with a certain caution as high
early strengths of cement in the 1 to 28-day range
can be achieved by finer grinding and higher
constituent ratio of C3S/C2S, where C3S is
Tricalcium Silicate and C2S is Dicalcium Silicate. In
such cements, the further growth of strength beyond
Page 800 of 1427

say 4 weeks may be much lower than that
traditionally expected. Therefore, further strength
tests shall be carried out for 56 and 90 days to fine
tune the mix design from strength considerations.
Cement conforming to 15:12330 shall be

used when sodium sulphate and magnesium sulphate
are present in large enough concentration to be
aggressive to concrete. The recommended threshold
values as -per 15:456 are sulphate concentration in
excess of 0.2 per cent in soil substrata or 300 ppm
(0.03per cent) in ground water. Tests to confirm
actual values of sulphate concentration are essential
when the structure is located near the sea coast,
chemical factories, agricultural land using chemical
fertilizers and sites where there are effluent
discharges or where soluble sulphate bearing ground
water level is high. Cement conforming to 15:12330
shall be carefully selected from strength
considerations to ensure that the minimum required
design strength can be achieved without exceeding
the maximum permissible cement content of 540 kg/
cu.m. of concrete.
Cement conforming to 15:8041 shall be used

only for precast concrete products after specific
Total chloride cement in cement shall in no

case exceed 0.05 per cent by mass of cement Also,
total sulphur content calculated as sulphuric
anhydride (SO3) shall in no case exceed 2.5 per cent
Page 801 of 1427

and 3.0 per cent when tri-calcium aluminate per cent
by mass is upto 5 or greater than 5 respectively.
1007. COARSE AGGREGATES
For plain arid reinforced cement concrete

(PCC and - RCC) or prestressed concrete (PSC)
works, coarse aggregate shall consist of clean, hard,
strong, dense, non-porous and durable pieces of
crushed stone, crushed gravel, natural gravel or a
suitable combination thereof or other approved inert
material. They shall not consist pieces of
disintegrated stones, soft, flaky, elongated particles,
salt, alkali, vegetable matter or other deleterious
materials in such quantities as to reduce the strength
and durability of the concrete, or to attack the steel
reinforcement. Coarse aggregate having positive
alkali-silica reaction shall not be used. All coarse
aggregates shall conform to IS:383 and tests for
conformity shall be carried out as per IS:2386, Parts
I to VIII.
The contractor shall submit for the approval

of the Engineer, the entire information indicated in
Appendix A of IS:383.
Maximum nominal size of coarse aggregate

for various structural components in PCC, RCC or
PSC, shall conform to Section 1700.
The maximum value for flakiness index for

coarse aggregate, shall not exceed 35 per cent. The
Page 802 of 1427

coarse aggregate shall satisfy the following
requirements of grading :
TABLE 1000-1 REQUIREMENTS OF COARSE

AGGREGATE
IS Sieve Size Per cent by Weight Passing the Sie

40mm 20mm’
63 mm 100 --
40 mm 95-100 100
20mm 30-70 95-100
12.5 mm -- --
10 mm 10-35 25-55
4.75 mm 0-5 0-10
1008. SAND/FINE AGGREGATES
For masonry work, sand shall conform to the

For plain and reinforced cement concrete

(PCC and RCC) or prestressed concrete (PSC)
works, fine aggregate shall consist of clean, hard,
strong and durable pieces of crushed stone, crushed
gravel, or a suitable combination of natural sand,
crushed stone or gravel. They shall not contain dust,
lumps, soft or flaky, materials, mica or other
deleterious materials in such quantities as to reduce
the strength and durability of the concrete, or to
attack the embedded steel. Motorised sand washing
Page 803 of 1427

machines should be used to remove impurities from
sand. Fine aggregate having positive alkali-silica
reaction shall not be used. All fine aggregates shall
conform to IS:383 and tests for conformity shall be
carried out as per IS:2386, (Parts I to VIII). The
Contractor shall submit to the Engineer the entire
information indicated in Appendix A of IS:383. The
fineness modulus of fine aggregate shall neither be
less than 2.0 nor greater than 3.5.
Sand/fine aggregate for structural concrete

shall conform to the following grading requirements
:
TABLE 1000-2
Per cent by Weight Passing th

IS Sieve Size
Zone I Zone II
10 mm 100 100
4.75 ram 90-100 90-100
236 mm 60-95 75-100
1.18 mm 30-70 55-90
600 micron 15-34 35-59
300 micron 5-20 8-30
150 micron 0-10 0-10
1009. STEEL
1009.1. Cast Steel
The use of cast steel shall be limited to
Page 804 of 1427

bearings and other similar parts. Steel for castings
shall conform to Grade 280-520N of IS: 1030. In
case where subsequent welding is unavoidable in the
relevant cast steel components, the letter N at the end
of the grade designation of the steel casting shall be
replaced by letter W. 0.3 per cent to 0.5 per cent
copper may be added to increase the corrosion
resistance properties.
1009.2. Steel for Prestressing
The prestressing steel shall conform to either

of the following :
(a) Plain hard drawn steel wire conforming

to IS:1785 (Part I) and IS:1785 (PartII).
(b) Cold drawn indented wire conforming to

IS:6003
(c) High tensile steel bar conforming to

IS:2090
(d) Uncoated stress relieved strands

1009.3. Reinforcement / Untensioned Steel
For plain and reinforced cement concrete

(PCC and RCC) or prestressed concrete (PSC)
works, the reinforcement / untensioned steel as the
case may be shall consist of the following grades of
Page 805 of 1427

reinforcing bars.
TABLE 1000-3
Grade Bar Type conforming to Characteristic. El

Designation governing IS Strength fy MPa
Specification
S 240 IS:432 Part I Mild Steel 240
Bar
S 415 IS: 1786 High Yield 415

Strength Deformed Bars
(HYSD)
Other grades of bars conforming to 15:432

and 13:1786 shall not be permitted.
All steel shall be procured from original

producers, no re-rolled steel |. shall be incorporated
in the work.
Only new steel shall be delivered to the site.

Every bar shall be inspected before assembling on
the work and defective, brittle or burnt bor shall be
discarded. Cracked ends of bars shall be discarded.
Fusion-bonded epoxy coated reinforcing bars

shall meet the requirements of 18:13620. Additional
requirements for the use of such reinforce-|”Went
bars have been given below :
(a) Patch up materials shall be procured in
Page 806 of 1427

sealed containers with certificates from
the agency who has supplied the fusion
bonded epoxy bars.
(b) PVC coated G.I. binding wires of 18G
shall only be used in conjunction with
fusion bonded epoxy bars.
(c) Chairs for supporting the reinforcement
shall also be of fusion bonded epoxy
coated bars.
(d) The cut ends and damaged portions shall
be touched up with repair patch up
material.
(e) The bars shall be cut by saw-cutting
rather than flame cutting.
(f) While bending the bars, the pins of work
benches shall be provided with PVC or
plastic sleeves.
(g) The coated steel shall not be directly
exposed to sun rays or rains and shall
be protected with opaque polyethelene
sheets or such other approved materials
(h) While concreting, the workmen or
trolleys shall not directly move on
coated bars but can move on wooden
planks placed on the bars.
When specified in the contract, protective

coaling prescribed by CECRI shall be provided in
conformance to specifications given in
Appendix1000/I. The CECRI coating process shall
be allowed to be implemented at the site of works
provided a representative of the Institute is present
Page 807 of 1427

throughout the duration of the coating process who
shall certify that the materials and workmanship are
in accordance with prescribed specifications
developed by the Institute.
1009.4. Grey Iron Castings
Grey Iron castings to be used for bearings

shall have the following minimum properties :
(i) Minimum ultimate tensile strength
370 MPa
(ii) Modulus of Elasticity
147000 MPa
(iii) Brinell Hardness
230 MPa
(iv) Shear Strength
370 MPa
(v) Compressive Strength
1370 MPa
The testing shall be as specified in IS:210.
1009.5. Steel Forgings
Forged steel pins shall comply with clause 3,

3A or 4 of IS: 1875 and steel forgings shall comply
with clause 3, 3A or 4 of IS:2004. Raw materials of
the forging will be taken as per IS: 1875 with
minimum reduction ratio of 1.8:1. Alternatively, if
forging is made from ingot, a minimum reduction
ratio between the ingot and forging will be 4:1.
Forging shall be normalised.
Page 808 of 1427

1009.6. Structural Steel
Unless otherwise permitted herein, all

structural steel shall before fabrication comply with
the requirements of the following Indian Standards:
IS:226 : Structural Steel (Standard

Quality)
IS:961 : Structural Steel (High Tensile)
IS:2062 : Weldable Structural Steel

IS.-8500 : Weldable Structural Steel
(medium & high strength qualities)
IS:1148 : Hot rolled rivet bars (upto

40mm dia) for structural purposes
IS:1149 : High (ensile rivet ban for

structural purposes
IS:1161 : Steel tubes for structural

purposes
IS:4923 : Hollow Steel sections for

structural use
15:11587 : Structural weather resistant

steel
IS:808 : Specifications for Rolled Steel
Page 809 of 1427

Beam, Channel and Angle Sections
IS:1239 : Mild Steel Tubes
IS:1730 : Dimension for Steel Plate,

sheet and strip for structural
and general
engineering purposes
JS:1731 : Dimension for Steel flats for

structural and general
IS:1732 : Dimension for round and

square steel bars for structural
and general
IS:1852 : Rolling and cutting tolerances

for hot rolled steel products
The use of structural steel not covered by the

above standards may be permitted with the specific
approval of the authority. Refer to Section 1900 for
further details.
1009.7. Stainless Steel
Stainless steel shall be austenitic chromium-

nickel steel, possessing rust, acid and heat resistant
properties conforming to IS:6603 and IS:6911.
Mechanical properties/grade for such stainless steel
Page 810 of 1427

shall be as specified the accepting authority, but in
no case be inferior to mild steel. Generally, stainless
steel is available as per AISI grades. AISI 304 which
• is equivalent to grade 04Crl8Ni110 of IS:6911
satisfies the requirements of mechanical properties
of structural steel. Other grades of stainless steel .for
specific purposes may be provided as per specific
requirements. For application in adverse/ corrosive
environment, stainless steel shall conform to AISI
316L or 02G17 Ni Mo2 of IS:6911.
1010. WATER
Water used for mixing and curing shall be

clean and free from injurious amounts of oils, acids,
alkalis, salts, sugar, organic materials or other
substances that may be deleterious to concrete or
steel. Potable Water is generally considered
satisfactory for mixing concrete. Mixing and curing
with sea water shall not be permitted. As a guide, the
following “Concentrations represent the maximum
permissible values :
(a) To neutralise 200 ml sample of water,

using phenolphthalein as an indicator, k
should not require more than 2 ml of 0.1
normal N2OH.
(b) To neutralise 200 ml sample of water,
using methyl orange as an indicator, it
should not require more than 10 ml of
0.1 normal HCL
(c) The permissible limits for solids shall be
Page 811 of 1427

as follows when tested in accordance
with 15:3025 :
P
e
r
m
i
s
s
i
b
l
e
L
i
m
i
t
s
(
m
a
x
)
Organic
200 mg/lit
Inorganic
3000 mg/lit
Sulphates (SO4)
Page 812 of 1427

500 mg/lit
Chlorides (CL)
500 mg/lit *
Suspended matter
2000 mg/lit
* In case of structures of lengths 30m and

below, the permissible limit of chlorides may be
increased upto 1000 mg/lit.
All samples of water (including potable

water) shall be tested and suitable measures taken
where necessary to ensure conformity of the water to
the requirements staled herein.
(d) The pH value shall not be less than 6.
1011. TIMBER
The timber used for structural purposes shall

conform to IS:883.
1012. CONCRETE ADMIXTURES

1012.1. General
Admixtures are materials added to the

concrete before or during mixing with a view to
modify one or more of the properties of concrete in
the plastic or hardened slate.
Concrete admixtures are proprietary items of

manufacture and shall be obtained only from
Page 813 of 1427

established manufacturers with proven track record,
quality assurance and full fledged laboratory
facilities for the manufacture and testing of concrete.
The contractor shall provide the following

information concerning each admixture after
obtaining the same from the manufacturer :
(a) Normal dosage and detrimental effects,

if any, of under dosage and over dosage.
(b) The chemical names of the main
ingredients in the admixtures.
(c) The chloride content, if any, expressed
as a percentage by the weight of the
admixture.
(d) Values of dry material content, ash
content and relative density of the
admixture which can be used for
Uniformity Tests.
(e) Whether or not the admixture leads to
the entertainment of air when used as per
the manufacturer’s recommended
dosage, and if so to what extent.
(f) Where two or more admixtures are
proposed 10 be used in any one mix,
confirmation as to their compatibility.
(g) There would be no increase in risk of
corrosion of the reinforcement or other
embedments as a result of using the
admixture.
1012.2. Physical and Chemical
Page 814 of 1427

Requirements
Admixtures shall conform to the

requirements of IS:9103. In addition, the following
conditions shall be satisfied :
(a) “Plasticisers” and “Super-Plasticisers”

shall meet the requirements indicated
for “Water reducing Admixture”.
(b) Except where resistance to freezing and
thawing and to disruptive action of de-
icing salts is necessary, the air content
of freshly mixed concrete in accordance
with the pressure method given in IS:
1199 shall not be more than 2 per cent
higher than that of the corresponding
control mix and in any case not more
than 3 per cent of the lest mix.
(c) The chloride content of the admixture
shall not exceed 0.2 per cent when
tested in accordance with IS:6925. In
addition, the maximum permissible
limit of chloride content of all the
constituents as indicated in Section
1700 shall also be observed.
(d) Uniformity tests on the admixtures are
essential to compare qualitatively the
com-position of different samples taken
from batch to batch or from the same
batch at different times.
The tests that shall be performed along with
Page 815 of 1427

permissible variations in the same are indicated
below :
 Dry Material Content : to be

within 3 per cent and 5 per cent of
liquid and solid admixtures
respectively of the value stated by
the manufacturer.
 Ash content : to be within 1 per

cent of the value staled by the
manufacturer.
Relative Density (for liquid admixtures) : to

be within 2 per ccm of the value stated by the
manufacturer.
(e) All tests relating to the concretes

admixtures shall be conducted
periodically at an independent laboratory
and compared with the data given by the
manufacturer.
1013. REINFORCED CONCRETE PIPES
Reinforced concrete pipes for highway

structures shall be of NP4 type conforming to the
1014. STORAGE OF MATERIALS
1014.1. General
Page 816 of 1427

All materials may be stored at proper places
so as to prevent their deterioration or intrusion by
and fitness for the work. The storage space must also
permit easy inspection, removal and restorage of the
materials. All such materials even though stored in
approved godowns/places, must be subjected to
acceptance test prior to their immediate use.
1014.2. Brick
Bricks shall not be dumped at site. They shall

be stacked in regular tiers as they are unloaded, to
minimise breakage and defacement The supply of
bricks shall be available at site at any time. Bricks
selected for use in different situations shall be
slacked separately.
1014.3. Aggregates
Aggregate stockpiles may be made on ground

that is denuded of vegetation, is hard and well
drained- If necessary, the ground shall be covered
with 50 mm plank.
Coarse aggregates, unless otherwise agreed

by the Engineer in writing, shall be delivered to the
site in separate sizes (2 sizes when nominal size is 25
mm or less and 3 sizes when the nominal size is 32
mm or more). Aggregates placed directly on the
ground shall not be removed from the stockpile
Page 817 of 1427

within 30 cm of the ground until the final cleaning
up of the work, and then only the clean aggregate
will be permitted to be used.
In the case of fine aggregates, these shall be

deposited at the mixing site not less than 8 hours
before use and shall have been tested and approved
by the Engineer.
1014.4. Cement
Cement shall be transported, handled and

stored on the site in such a manner as to avoid
deterioration or contamination. Cement shall be
stored above ground level in perfectly dry and water-
tight sheds and shall be stacked not more than eight
bags high. Wherever bulk storage containers are
used their capacity should be sufficient to cater to
the requirement at site and should be cleaned at least
once every 3 to 4 months.
Each consignment shall be stored separately

so that it may be readily identified and inspected and
cement shall be used in the sequence in which it is
delivered at site. Any consignment or part of a
consignment of cement which had deteriorated in
any way, during storage, shall not be used in the
works and shall be removed from the site by the
Contractor without charge to the Employer.
The Contractor shall prepare and maintain

proper records on site in respect of delivery,
Page 818 of 1427

handling, storage and use of cement and these
records shall be available for inspection by the
Engineer at all times.
The Contractor shall make a monthly return

to the Engineer on the date corresponding to the
interim certificate date, showing the quantities of
cement received and issued during the month and in
stock at the end of the month.
1014.5. Reinforcement /Untensioned Steel

The reinforcement bars, when delivered on
the job, shall be stored 5, above the surface of the
ground upon platforms, skids, or other supports, and
shall be protected from mechanical injury and from
deterioration by exposure.
1014.6. Prestressing Materials
All prestressing steel, sheathing, anchorages

and sleeves or coupling must be protected during
transportation, handling and storage. The
prestressing steel, sheathing and other accessories
must be stored under cover from rain or damp
ground and protected from the ambient atmosphere
if it is likely, to be aggressive. Storage at site must
be kept to the absolute minimum.
(a) Tendon : Wire, strand and bar from
which tendons are to be fabricated
shall be stored about 300mm above the
ground in a suitably covered and
closed space so as to avoid direct
Page 819 of 1427

climatic influences and to protect them
from splashes from any other materials
and from the cutting operation of an
oxy-acetylene torch or arc welding
process in the vicinity. Under no
circumstances, tendon material shall
be subjected to’ any welding operation
or on site heat treatment or metallic
coaling such as galvanising. Storage
facilities and the procedures for
transporting material into or out of
store, shall be such that the material
does not become kinked or notched.
Wire or strand shall be stored in large
diameter coils which enable the
tendons to be laid out straight. As a
guide, for wires above 5mm dia, coils
of about 2m dia without breaks or
joints shall be obtained from
manufacturer and stored. Protective
wrapping for tendons shall be
chemically neutral. All prestressing
steel must be provided with temporary
protection during storage.
(b) Anchorage Components : The handling
and storing procedures shall maintain
the anchorage components in a
condition in which they can
subsequently perform their function to
an adequate degree. Components shall
be handled and stored so that
mechanical damage and detrimental
Page 820 of 1427

corrosion are prevented. The corrosion
of the gripping and securing system
shall be prevented. The use of
correctly formulated oils and greases
or of other corrosion preventing
material is recommended where
prolonged storage is required. Such
protective material shall be guaranteed
by the producer to be non-aggressive
and non-degrading.
Prestressing steel shall be stored in a closed

store having single door with double locking
arrangements and no windows. Also the air inside
the store shall be kept dry as far as possible by using
various means to the satisfaction of the Engineer.
Also instrument measuring the air humidity shall be
installed inside the store. This is with a view to
eliminating the possibility of initial rusting of
prestressing steel during storage. The prestressing
steel shall be coated with water solvable grease. The
prestressing steel should be absolutely clean and
without any signs of rust.
All prestressing steel shall be stored at least

30 cm above ground level and it shall be invariably
wrapped by protective cover of tar paper or
polythene or any other approved material.
The Contractor should see that prestressing

steel shall be used within 3 months of its
manufacture. He should chalk out his programme in
Page 821 of 1427

this respect precisely, so as to avoid initial corrosion
before placing in position.
1014.7. Water
Water shall be stored in containers/tanks

covered at top and cleaned at regular intervals in
order to prevent intrusion by foreign matter or
growth of organic matter. Water from shallow,
muddy or marshy surface shall not be permitted. The
intake pipe shall be enclosed to exclude silt, mud,
grass and other solid materials and there shall be a
minimum depth of 0.60 m of water below the intake
at all times.
1015. TESTS AND STANDARD OF

ACCEPTANCE
All materials, even though stored in an

approved manner shall be subjected to an acceptance
test prior to their immediate use.
Independent testing of cement for every

consignment shall be done by the Contractor at site
in the laboratory approved by the Engineer before
use. Any cement with lower quality than those
shown in manufacturer’s certificate shall be debarred
from use. In case of imported cement, the same
series of tests shall be carried out before acceptance.
1015.1. Testing and Approval of Material
Page 822 of 1427

The Contractor shall furnish test certificates
from the manufacturer/ supplier of materials along
with each batch of material(s) delivered to site.
The Contractor shall set up a field laboratory

with necessary equipment for testing of all materials,
finished products used in the construction as per
requirements of conditions of contract and the
relevant specifications. The testing of all the
materials shall be carried out by the Engineer or his
representative for which the Contractor shall make
all the necessary arrangements and bear the entire
cost.
Tests which cannot be carried out in the field

laboratory have to be got done at the Contractor’s
cost at any recognised laboratory / testing
establishments approved by the Engineer.
1015.2. Sampling of Materials
Samples provided to the Engineer or his

representative for their retention are to be in labelled
boxes suitable for storage.
Samples required for approval and testing

must be supplied well in advance by at least 48 hours
or minimum period required for carrying out
relevant tests to allow for testing and approval.
Delay to works arising from the late submission of
samples will not be acceptable as a reason for delay
in the completion of the works.
Page 823 of 1427

If materials are brought from abroad, the cost
of sampling/testing whether in India or abroad shall
be borne by the Contractor.
1015.3. Rejection of Materials not

Conforming to the Specifications
Any stack or batch of material(s) of which
sample(s) does not conform to the prescribed tests
and quality shall be rejected by the Engineer or his
representative and such materials shall be removed
from site by the Contractor at his own cost. Such
rejected materials shall not be made acceptable by
any modifications.
1015.4. Testing and Approval of Plant and

Equipment
All plants and equipment used for preparing,

testing and production of materials for incorporation
into the permanent works shall be in accordance with
manufacturer’s specifications and shall be got
approved by the Engineer before use.
Page 824 of 1427

Pile Foundations
1100
Pile Foundations
Page 825 of 1427

1101. DESCRIPTION
1101.1. This work shall consist of

construction of all types of piles for structures in
accordance with the details shown on the drawings
and conforming to the requirements of these
specifications.
1101.2. The construction of pile foundations

requires a careful choice of the piling system
depending upon sub-soil conditions and loading
characteristics and type of structure. The permissible
limits of total and differential settlements,
unsupported length of pile under scour, impact/
entanglement of floating bodies and any other
special requirements of project are also equally
important criteria for selection of the piling
system. The method of installing the piles,
including details of the equipment shall be
submitted by the Contractor and got approved
from the Engineer.
1101.3. The work shall be done as per

IS:2911 except as modified herein.
1102. SUB-SURFACE INVESTIGATION
1102.1. The complete sub-surface

investigation of strata in which pile foundations
are proposed shall be carried out in advance and by
in-situ pile tests. For details of geotechnical sub-
surface explorations reference may be made to
Page 826 of 1427

Section 2400. At least one core-hole for every
foundation of the bridge shall be executed. Borings
should be carried upto sufficient depths so as to
ascertain the nature of strata around the pile shaft
and below the pile tip. However, depth of boring
shall not be less than :
i) 1.5 limes estimated length of

pile in soil but not less than IS
m beyond the probable length
of pile
ii) 15 times diameter of pile in
weak/jointed rock but
minimum 15 m in such rock
iii) 4 times diameter of pile in
sound, hard rock but
minimum 3 m in such rock
1102.2. The sub-surface investigation shall

define adequately stratification of sub-strata
including the nature and type of strata, its variation
and extent and specific properties of the same. The
investigation shall be adequate for the purpose of
selection of appropriate piling system and for
estimating design capacities for different diameters
and length of piles.
1102.3. Pressure meter tests may be used in

the case of rock, gravel or soil for direct
evaluation of strength and compressibility charac-
teristics. Though these tests are of specialised
nature they are most appropriate for
Page 827 of 1427

difficult/uncertain sub-strata especially for
important projects.
1102.4. For piles socketed into rocks, it is

necessary to determine the uniaxial compressive
strength of the rock and its quality.
The investigation shall also include location

of ground water table and other parameters including
results of chemical tests showing sulphate and
chloride content and any other deleterious chemical
content in soil and/or ground water, likely to affect
durability.
1103. TYPE OF PILES
The piles may be of reinforced concrete,

prestressed concrete, steel or timber. The piles may
be of solid or hollow sections or steel cased piles
filled with concrete. Concrete piles may be driven ‘
cast-in-situ or precast or bored cast-in-situ or precast
piles driven into preformed bores. The shape of piles
may be circular, square, hexagonal, octagonal, “H”
or “I” Section.
1104. MATERIALS
1104.1. The basic materials shall conform to

the specifications for materials given in Section
1000. The specifications for steel reinforcement,
structural concrete, prestressed concrete and
structural steel to be used in pile foundations shall be
Page 828 of 1427

as given in the relevant sections.
1104.2. Concrete in Piles
Grade of concrete to be used in cast-in-situ

piles shall not be less than M 20 and the cement
content shall not be less than 400 kg per cubic meter
of concrete. Grades of concrete for precast
reinforced and prestressed concrete piles shall not be
less than M 25 and M 35 respectively. Maximum
water cement ratio shall be 0.5 for cast-in-situ piles
and 0.45 for precast piles.
The minimum slump of concrete for driven

cast-in-situ piles shall be 100 mm to 150 mm and
that of bored cast-in-silu piles 150 mm to 200 mm.
The slump should not exceed 200 mm in any case.
Concrete mix should have homogeneous

mixture with required workability for the system of
piling adopted. Suitable and approved admixtures
may be used in concrete mix where necessary.
Where piles are exposed to action of harmful

chemicals or severe conditions of exposure due to
presence of sulphate, chloride etc, it may be
preferable to opt for higher grades of concrete
restricting water cement ratio to 0.45. Special types
of cement, such as sulphate resistant cement may be
used where considered appropriate.
Page 829 of 1427

1105. TEST PILES
1105.1. Test piles which are shown on the

drawings or specified in the contract or installed by
the Contractor on his own to determine the lengths
of piles to be furnished shall conform to the
requirements for piling as indicated in these
specifications, if they are to be incorporated in the
completed structure.
Test piles that are to become a part of the

completed structure shall be installed with the same
type of equipment that is proposed to be used for
piling in the actual structure.
Test piles which are not to be incorporated in

the completed structure shall be removed to at least
600 mm below the proposed soffit level of pile cap
and the remaining hole shall be backfilled with earth
or other suitable material.
The piles shall be load tested in accordance

with provisions laid down in this section.
1106. PRECAST\CONCRETE PILES
1106.1. General
Precast concrete piles shall be of the size and

shape as shown in the approved drawings. If a square
section is employed, the corners shall be chamfered
at least 25 mm unless otherwise specified on the
Page 830 of 1427

drawings. The length of pile shall not normally
exceed 25 metres. However, where special
equipments for handling and installation are
available to the satisfaction of the Engineer, longer
length could be permitted.
Piles shall be cast with a driving point and

for hard driving, shall be shod with a metal shoe
1106.2. Stacking, Storing and Handling
Care shall be taken that at all stages of

transporting, lifting and handling, piles are not
damaged or cracked. During transport and stacking
of piles, they shall be supported at the same points as
those provided for lifting purposes. If the piles are
put down temporarily during handling, they shall be
placed on trestles or blocks located at the same
points.
Piles shall be stored at least 300 mm above

firm level ground which is not liable to unequal
subsidence or settlement under the weight of the
stack of piles. They shall be placed on timber
supports which are level and spaced so as to avoid
bending. The supports shall be vertically one above
the other. Spaces shall be left round the piles to
enable them to be lifted without difficulty. The order
of stacking shall be such that the older piles can be
withdrawn without disturbing newer piles. Separate
stacks shall be provided for different lengths of piles.
Page 831 of 1427

Where piles are stacked in layers, the number of
layers shall not exceed three. Whenever curing is
needed during storage, arrangements shall be made
to enable the piles to be watered. For detailed
precautions with regard to curing operations
specifications for structural concrete given in Section
1700 shall apply.
Before the operation of handling and driving

the piles, the minimum periods counted from the
time of casting shall be allowed for as indicated in,
Table 1100-1. Prestressed piles shall not be lifted or
handled until fully stressed.
TABLE 1100-1 TIME FOR CURING PRECAST

PILES
Type of cement used in

Minimum periods from t
casting the pile
Strike side- End of Lift fr
shutters wet curing casting
(hours) (days) (day
Ordinary Portland 24 7 10
Rapid hardening Portland 12 7 7
1166.3. Lengthening of Files
Where a pile is to have another length cast on

it during driving, the longitudinal reinforcement
shall preferably be joined by full penetration butt
welding. The concrete at the top of the original pile
Page 832 of 1427

shall be cut down to expose not less than 200 mm of
the bars to avoid spalling of the concrete by heat.
The added bars have to be held accurately and
rigidly in position during welding. Where facilities
on site are insufficient to make proper butt welding
practicable, the joint may be made by lapping. The
reinforcement at the head of pile will need to be
exposed for full anchorage length or 600 mm
whichever is greater and the new bars over-lapped
for this distance. Unless otherwise specified, the
extension of the pile shall be formed to the same
cross-sectional profile and with concrete of at least
the same strength as that specified for the-original
pile. The stirrup spacing shall in no case be greater
than 150 mm. Not more than one extension shall be
permitted. In case more than one extension is
permitted by the Engineer, only approved
mechanical couplers shall be used.
Driving shall not be resumed until :

(i) The strength of the concrete in the
extension is at least equal to the
specified characteristic strength of
concrete in pile, and
(ii) The approval of the Engineer has been

obtained.
1106.4. Removal of Surplus Length
Any length of pile surplus to that required for

incorporation in the structure shall be cut off neatly
Page 833 of 1427

and removed. During the process of cutting off, it
shall be ensured that projecting reinforcement to be
anchored into the pile cap and the prestressing
strands/wires are not damaged. When stripping
prestressed concrete piles, shock release of tendons
shall be avoided. Reference may also be made to
clause 7.7.1. of IS:2911 (Part I Section 3) in this
connection.
1106.5. Risen Piles
Level reading should be taken on each pile

after driving and again after all the piles are driven.
Piles which are found to have risen due to ground
heave or as a result of driving adjacent piles, shall be
re-driven to the original depth or resistance unless
re-driving tests on adjacent piles have shown this to
be unnecessary.
1106.6. Manufacture
The pile should be cast in one continuous

operation from end to end of each pile. Manufacture
of precast concrete piles shall conform to the
guidelines contained in clause Nos. 7.1,7.2 and 7.3
of IS:2911 (Part I, Section 3).
Pile shall be provided with suitable shoe for

protecting the point of the pile during driving in hard
ground.
Piles shall not be moved from casting bed
Page 834 of 1427

until the concrete has hardened sufficiently.
Piles shall not be driven in less than 28 days

after casting or unless their strength at the time of
driving is at least that specified for 28 days.
1106.7. Prestressed Concrete Piles
Additional specifications for precast

prestressed concrete piles shall conform to those
contained in clause 8 of IS:29ll (Part I Section 3).
1107. CAST-IN-SITU CONCRETE PILES
Cast-in-situ concrete piles may be either

installed by making a bore into the ground by
removal of material or by driving a metal casing
with a shoe at the tip and displacing the material
laterally. The two types of piles are termed as “bored
piles” arid “driven piles” respectively. Cast-in-situ
concrete piles may be cast in metal shells which may
remain permanently in place. However, other types
of cast-in-situ concrete piles, plain or reinforced,
cased or uncased, may be used if in the opinion of
the Engineer the soil conditions permit their use and
if their design and the methods of placing are
satisfactory.
The metal casing shall be of sufficient

thickness and strength to hold its original form and
show no harmful distortion after it and adjacent
casings have been driven and the driving core, if
Page 835 of 1427

any, has been withdrawn.
Cast-in-situ concrete driven piles shall be

installed using a properly designed detachable shoe
at the bottom of the casing. Certain specific
requirements of cast-in-situ driven piles shall be as
per Clauses 1110 and 1111.
Any liner or bore-hole which is improperly

located or shows partial collapse that would affect
the load carrying capacity of the pile, shall be
rejected or .repaired as directed by the Engineer at
the cost of the Contractor.
Wherever practicable, concrete should be

placed in a clean dry-hole. Where concrete is placed
in dry and there is casing present, the top 3 m of the
pile shall be compacted using internal vibrators. The
concrete should invariably be poured through a
tremie with a funnel so that the flow is directed and
concrete can be deposited in the hole without
segregation.
Where the casing is withdrawn from cohesive

soils for the formation of cast-in-situ pile, the
concreting should be done with necessary
precautions to minimise the softening of the soil by
excess water. Where mud flow conditions exist, the
casing of cast-in-situ piles shall not be allowed to be
withdrawn.
Care shall be taken during concreting to
Page 836 of 1427

prevent as far as possible the segregation of the
ingredients. The displacement or distortion of
.reinforcement daring concreting and also while
extracting the tube-shall be avoided.
If the concrete is placed inside precast

concrete tubes or consists of precast sections, these
shall be free from cracks or other damage before
being installed.
The concrete shall be properly graded, shall

be self-compacting and shall not get mixed with soil,
excess water, or other extraneous matter. Special
care shall be taken in silty clays and other soils with
the tendency to squeeze into the newly deposited
concrete and cause necking. Sufficient head of green
concrete shall be maintained to prevent inflow of soil
or water into the concrete.
The placing of concrete shall be a continuous

process from the toe level to the top of the pile. To
prevent segregation, a tube or tremie pipe as
appropriate shall be used to place concrete in all
piles.
To ensure compaction by hydraulic static

heads, rate of placing concrete in the pile shaft shall
not be less than 6 m (length of pile) per hour.
Bored cast-in-situ piles in soils which are

stable, may often be installed with only a small
casing length at the top. A minimum of 2.0 m length
Page 837 of 1427

of top of bore shall invariably be provided with
casing to ensure against loose soil falling into the
bore. In cases in which the side soil can fail into the
hole, it is necessary to stabilise the side of the bore
hole with drilling mud, or a suitable steel casing. The
casing may be left in position permanently specially
in cases where- the aggressive action of the ground
water is to be avoided, or in the cases of piles built in
water or in cases where significant length of piles
could be exposed due to scour.
For bored cast-in-situ piles, casing/liner shall

be driven open ended with a pile driving hammer
capable of achieving penetration of the liner to the
length shown on the drawing or as approved by the
Engineer Materials inside the casing shall be
removed progressively by air lift, grab or percussion
equipment or other approved means.
Where bored cast-in-situ piles are used in

soils liable to flow, the bottom of the casing shall be
kept enough in advance of the boring tool to prevent
the entry of soil into the casing, thus preventing the
formation of cavities and settlements in the adjoining
ground. The water level in the casing should
generally be maintained at the. natural ground water
level for the same reasons. The joints of the casing
shall be made as tight as possible to minimise inflow
of water or leakage of slurry during concreting.
Boring shall be carried out using rotary or
percussion type equipment. Unless otherwise
approved by the Engineer, the diameter of the bore-
Page 838 of 1427

holes shall be not more than the inside diameter of
the liner.
Pior to the lowering of the reinforcement

cage into the pile shaft, the shaft shall be cleaned of
all loose materials. Cover to reinforcing steel shall
be maintained by suitable spacers.
The diameter of the finished pile shall not be

less than that specified and a continuous record shall
be kept by the Engineer as to the volume of concrete
placed in relation to the pile length cast.
Before concreting under water, the bottom of

the hole shall be cleaned of drilling mud and all soft
or loose material very carefully. In case a hole is
bored with use of drilling mud, concreting should
not be taken up when the specific gravity of bottom
slurry is more than 1.2. The drilling mud should be
maintained at 1.5m above the ground water level.
Concreting under water for cast-in-situ

concrete piles-may be done either with the use of
tremie method or by the use of an approved method
specially designed to permit under water placement
of concrete.
General requirements and precautions for

concreting under water are as follows :
(a) The concreting of a pile must be

completed in one continuous operation.
Page 839 of 1427

Also, for bored holes, the finishing of
the bore, cleaning of the bore, lowering
of reinforcement cage and concreting of
pile for full height must be accomplished
in one continuous operation without any
stoppage.
(b) The concrete should be coherent, rich in
cement with high slump and restricted
water cement ratio.
(c) The tremie pipe will have to be large
enough with due regard to the size of
aggregate. For 20 mm aggregate the
tremie pipe should be of diameter not
less than 150 mm and for larger
aggregate, larger diameter tremie pipes
may be necessary.
(d) The first charge of concrete should be
placed with a sliding plug pushed down
the tube ahead of it to prevent mixing of
water and concrete.
(e) The tremie pipe should always penetrate
well into the concrete with an adequate
margin of safety against accidental
withdrawal if the pipe is surged to
discharge the concrete.
(f) The pile should be concreted wholly by
tremie and the method of deposition
should not be changed pen way up she
pile to prevent the laitance from being
entrapped within the pile
(g) All tremie tubes should be scrupulously
cleaned alter use
Page 840 of 1427

The minimum embedment of cast-in-situ
concrete piles into pile cap shall be 150 mm. Any
defective concrete at the head of the completed pile
shall be cut away and made good with new concrete.
The clear cover between the bottom reinforcement in
pile cap from the top of the pile shall be not less than
25 mm. The reinforcement in the pile shall be
exposed for full anchorage length to permit it to be
adequately bonded into the pile cap. Exposing such
length shall be done carefully to avoid damaging the
rest of the pile. In cases where the pile cap is to be
laid on ground, a levelling course of M 15 nominal
mix concrete 100 mm thick shall be provided.
Defective piles shall be removed or left in place as
judged convenient without affecting the performance
of adjacent piles or pile cap. Additional piles shall be
provided to replace the defective piles.
1108. STEEL PILES
Steel piles shall be “H” or “I” sections as

shown on the drawings and shall be of structural
steel conforming to the specifications given in
Section 1000.
Steel piles shall be protected by suitable anti-

corrosive painting as specified on the drawing. Piles
shall be stored above the ground using protective
packing to minimise damage to surface coating.
Each pile shall be supplied preferably in one piece
without splices.
Page 841 of 1427

At the option of the Contractor, steel piling
consisting of structural Steel plates welded together
may be substituted for the rolled sections specified,
provided that the depth, width and average
thicknesses are at least equal lo those of the rolled
sections, the steel plates conform to specification
given in Section 1000, the flanges are welded to the
web with continuous fillet welds on either side of the
web, and the welding conforms to Clause 1904.8 of
these specifications.
The length of the steel pile may be built up in

sections either before or during driving operations.
The sections shall be of identical cross-section. Pile
splices shall be made with full penetration butt welds
over the whole cross-section. Pile splices shall
develop at least the yield strength of pile.
The connections shall be made by butt-

welding the entire cross-section in accordance with
the provisions in Clause 1904.8 of these
specifications. Care shall be taken to properly align
the sections connected so that the axis of the pile will
be straight. The number of welded connections in the
length of pile shall be as few as possible.
1109. TIMBER PILES
The Engineer shall stamp each pile on the

butt with a stamp which shall make an impression
that is readily legible. Treated limber piles will be
Page 842 of 1427

inspected by the Engineer after treatment.
Untreated timber may be used as test piles.
Untreated timber piles and treated timber

piles shall be of approved quality.
Treated timber piles shall be driven within 6

months after treatment.
Timber piles shall be furnished with tip

protection and shall be protected by the use of steel
straps as hereinafter specified. Tip protection shall
be suitable for use on timber piling of the size to be
driven. Details of tip protection shall be furnished to
the Engineer for review and approval before driving
piles. Not less than 2 separate steel straps shall be
placed within 600 mm of the butt of each pile after
the pile is square cut. Not less than 2 separate steel
straps shall be placed within 300 mm of the Up of
each pile. Additional intermediate steel straps shall
be placed at not more than 3 metres centre measured
along the length of the pile.
Timber piles which are to be capped shall be

separately cut off so that true bearing is obtained on
every pile. Piles inaccurately cut off shall be
replaced. Splicing of timber piles shall not be
permitted except by written permission of the
Engineer.
1110. DRIVING EQUIPMENT
Page 843 of 1427

Piles or their casings may be driven with any
type of drop hammer, diesel hammer or single-acting
steam or compressed air hammer, provided they
penetrate to the prescribed depth or attain the
designed resistance without being damaged. The
weight or power of the hammer should be sufficient
to ensure a penetration of at least 5 mm per blow,
unless rock has been reached. It is always preferable
to employ the heaviest hammer practicable and to
limit the stroke, so as not to damage the pile. The
minimum weight of the hammer shall be 2.5t. In the
case of precast concrete piles the mass of the
hammer shall be not less than 30 times the mass of
300 mm length of pile.
Steam or air hammers shall be furnished

along with boiler or air compressor of capacity at
least equal to that specified by the manufacturer of
the hammers. The boiler or air compressor shall be
equipped with an accurate pressure gauge at all
times. The valve mechanism and other parts of
steam, air or diesel hammers shall be maintained in
first • class condition so that the length of stroke and
number of blows per minute for which the hammer
is designed, will be obtained. Inefficient steam, -air
or diesel hammers shall be removed from the work.
1111.DRIVING
1111.1. General Procedure
Page 844 of 1427

Details of the equipment and the method
proposed for driving the piles shall be submitted
with the tender for scrutiny and approval of the
Engineer. Piles shall be installed from firm ground
or from temporary supports or from fixed platform.
The arrangement shall provide sufficient rigidity to
ensure accuracy of pile driving under all conditions
of tide, stream flow or hammer drop.
During driving the top of pile shall be

protected by a suitable helmet of substantial steel
construction. The helmet shall provide uniform
bearing across the top of the pile and shall hold the
pile centrally under the hammer. No pile shall be
driven unless inspected and approved by the
Engineer.
Piles shall be driven from a fixed frame of

sufficient rigidity to ensure accuracy of driving
within specified tolerances. Forces producing undue
bending or torsional stresses in piles shall not be
applied during driving. The force of the hammer
shall be directed centrally and axially during driving.
The stroke of a single acting or drop hammer

shall be limited to 1.2 m unless otherwise permitted
by the Engineer. A shorter stroke may be necessary
when there is danger of damaging the pile.
Piles shall not be bent or sprung into position

but shall be effectively guided and held on-line
during the initial stages of driving. Attempts to
Page 845 of 1427

correct any tendency for the pile to run off-line by
the application of significant horizontal restraint will
not be permitted. Shortly after the Commencement
of driving and at regular intervals throughout the
driving operation, checks shall be made to ensure
that the pile frame does not exert any undue lateral
force on the pile due to restraint within the helmet.
If the indications are that a pile will finish

outside the specified tolerances, driving operations
on that pile will cease. The pile shall be withdrawn,
the hole filled and the pile re-driven at no extra cost.
To avoid the possibility of premature “set-

up” pile driving shall be continuous in the later
stages, without any deliberate stops. (Delays of an
hour or less may lead to significant “set-up” in piles
i.e. resistance to further driving increases after
driving is stopped).
If any pile is damaged in any way during

driving, ii shall be repaired or replaced as directed by
the Engineer, at no extra cost. If during driving, the
head of a pile is damaged to the extent that further
driving is not possible, the head shall be cut off and
driving continued. The cost of cutting off shall be
borne by the Contractor and where, as a result of
such cutting off the head, the pile is too short, the
Contractor, shall, at his own cost, supply and splice
on sufficient length of pile to restore the pile to its
correct length.
Page 846 of 1427

Piles should be driven to the minimum
acceptable penetration shown on the drawings. This
may require preboring and/or jetting as indicated in
these specifications with the full approval of the
Engineer.
Piles shall be driven to nominal refusal or the

required ultimate dynamic capacity nominated on the
drawings or until the top of the pile is at the level
required and specified on the drawing whichever
gives the lowest toe elevation. The Engineer’s
decision in these matters shall be final. Nominal
refusal shall be taken as equivalent to 25 mm total
penetration for the final 20 blows using a hammer of
driving energy as specified and shall be used as the
criterion for acceptance for piles founded on rock.
Severe driving which results in an average set per
blow less than 0.5 mm will not be permitted.
Where hard drilling is encountered because

of dense strata or obstructions located above the
predetermined pile tip level, nominal refusal shall
not be considered to have been achieved unless the
Engineer is satisfied that the total number of blows,
as the average driving resistance specified for
nominal refusal, indicates that further driving will
not advance the pile through dense strata or
obstructions.
The pile shall be driven as accurately as

possible to the vertical or to specified batter.
Straining the pile into position can damage it and the
Page 847 of 1427

driving equipment should be adjusted as much as
possible to follow the position of the pile. Any
deviation from the proper alignment shall be noted
and promptly reported to the Engineer. If the
deviation is to such an extent that the resulting
eccentricity cannot be taken care of by strengthening
the pile cap or pile ties, such a pile shall, at the
discretion of the Engineer, be replaced or
supplemented by an additional pile. Unless
otherwise, specified, the permissible positional
deviation for piles shall be limited to those indicated
in Clause 1116.
Care shall be taken not to damage the pile by

over-driving. Any sudden change in the rate of
penetration which cannot be ascribed to the nature of
the ground shall be noted and its cause ascertained, if
possible, before driving is continued.
When employing a tube which is

subsequently withdrawn for the formation of cast-in-
situ pile, consideration shall be given to the
possibility of doing harm to a pile recently formed
by driving the tube nearby before the concrete has
sufficiently set. The danger of doing harm is greater
in compact soils than loose soils. No pile shall be
bored or driven within 3 m of a newly cast pile until
at least 24 hours after completion of its installation.
Driving piles in loose sand tends to compact

the sand which in turn increases the skin friction.
Therefore, driving a number of friction piles in a
Page 848 of 1427

group shall proceed outward from the centre as
otherwise it will be difficult to drive the inner piles
to the same depth as the others.
In the case of stiff clay also, the driving for a

group of piles shall proceed outward from the centre.
However, in case of very soft soil, the driving may
proceed from outside to inside, so that the soil is
restrained from flowing out during driving
operations.
If there is a major variation between the

depth at which adjacent foundation piles in a group
meet refusal, a boring shall be made nearby to
ascertain the cause of this difference. If the boring
shows that the soil contains pockets of highly
compressive material below the level of the shorter
pile, it will be necessary to enforce penetration of all
the piles to a level below the bottom of the zone
which shows such pockets.
1111.2. Preboring and Jetting
Driving of the piles may be assisted by

preboring holes or by the use of jets or both subject
to the approval of the Engineer. These may be used
essentially to achieve the minimum penetration
shown on the drawings where such penetration is not
reached under normal conditions of driving indicated
in Clause 1111.1.
The diameter, of the hole shall not be greater
Page 849 of 1427

than the diagonal dimension of the pile less 100 mm.
The maximum depth of the preboring

shall be such that the specified set (or less) is
obtained when the toe of the pile is at founding level.
Preboring shall be as approved by the Engineer and
shall not extend below one metre above the founding
level and the pile shall be driven to at least one metre
below the prebored hole. To ensure that the pile is
properly support xl laterally in the hole, any space
remaining around the pile at the ground level after
driving is finished shall be backfilled, with approved
granular material.
When water jetting is used, at least two jets

shall be attached to the pile symmetrically when this
type of technique is used. The volume and pressure
of water at the outlet nozzles shall be sufficient to
freely erode material adjacent to the toe of the pile.
The maximum depth of jetting shall be such that the
specified set (or less) is obtained when the toe of the
pile is at founding level. Jetting shall cease as
directed by the Engineer and shall not proceed below
one metre above the founding level and the pile shall
be driven at least one metre below the pre-bored
hole.
To avoid very hard driving and vibration in

materials such as sand, jetting of piles by means of
water may be carried out only by express permission
of the Engineer and in such a manner as not to
impair the bearing capacity of piles already in place,
Page 850 of 1427

the stability of the soil or the safety of any adjoining
buildings. Details of the arrangement for jetting shall
be got approved from the Engineer in advance.
If, for jetting, large quantities of water are

used, it may be necessary to make provision for
collection of water when it comes to the ground
surface, so that the stability of the piling plant is not
endangered by the softening of the ground.
Jetting shall be stopped before completing

the driving which shall always be finished by
ordinary methods. Jetting shall be stopped if there is
any tendency for the pile ‘tips to be drawn towards
the pile already driven owing to the disturbance to
the ground.
1112. RAKER (INCLINED) PILES
The maximum rake to be permitted in piles

shall not exceed the following :
i) 1 in 8 for large diameter cast-in-situ
piles viz 0.75 m diameter and above
ii) 1 in 5 for smaller diameter cast-in-situ
piles
iii) 1 in 4 for precast driven piles
1113. PILE TESTS
1113.1. General
The bearing capacity of a single pile may be
Page 851 of 1427

determined from test loading a pile. The load test on
a concrete pile may not be carried out earlier than 28
days from the time of casting of the pile.
There shall be two categories of tests on

piles, namely, initial tests and routine tests. Initial
tests should be carried out on test piles which are not
to be incorporated in the work. Routine tests shall be
carried out as a check on- working piles. The number
of initial and routine tests on piles shall be as
determined by the Engineer depending upon the
number of foundations, span length, type of
superstructure and uncertainties of founding strata.
In any case, the initial load tests shall not be less
than 2 in number, while the routine load tests shall
not be less than 2 per cent of the total number of
piles in the structure nor less than 2 in number.
The above stipulations hold good for both

vertical as well as lateral load tests on pile
foundations.
However, both initial and routine tests may

be suitably increased for important structures or
cases with large variation in the subsurface strata.
The methodology of carrying out load tests

and of arriving at safe load on piles shall conform to
IS:2911 (Part IV).
In case of any doubt of workmanship or load

carrying capacity of working piles not subjected to
Page 852 of 1427

routine tests, or when ordered. by the Engineer, or
when provided in the contract, load tests on working
piles may be supplemented by non-destructive
testing. Such tests may include “Integrity Testing” of
concrete in the installed pile and utilisation of “Pile
Driving Analyser” which gives an indication of pile
capacity in end bearing and side friction.
1114. PILE CAP
Pile Caps shall be of reinforced concrete. A

minimum offset of 150 mm shall be provided
beyond the outer faces of the outer most piles in the
group. If the pile cap is in contact with earth at the
bottom, a levelling course of minimum 100 mm
thickness of M 1S nominal mix concrete shall be
provided.
The attachment of the pile head to the cap

shall be adequate for the transmission of loads and
forces. A portion of pile top may be stripped of
concrete and the reinforcement anchored into the
cap. Manual chipping may be permitted after three
days of pile casting, while pneumatic tools for
chipping shall not be used before seven days after
pile casting. The top of pile after stripping shall
project at least 150 mm into the pile cap. A layer of
surface reinforcement may be provided with a cover
of 25 mm to retain the integrity of concrete below
the main cap reinforcement which is to be laid 25
mm above the pile top.
Page 853 of 1427

Concreting of the pile cap shall be carried out
in dry conditions. The bottom of the pile cap shall be
laid preferably as low as possible taking account of
the water level prevalent at the time of casting.
The top of concrete in a pile shall be brought

above cut-off level to permit removal of all laitance
and weak concrete before pile cap is laid. This will
ensure good concrete at the cut-off level.
1115. IMPORTANT
CONSIDERATIONS,
INSPECTION/PRECAUTIONS
FOR DIFFERENT TYPES OF
PILES
1115.1. Driven Cast-in-Situ Piles
1115.1.1. Specialist literature and the

guidelines from the pile construction industry shall
be consulted regarding the method of installation,
equipment and accessories for pile driving and
recording of data.
1115.1.2. During installation of piles the

final “set” of penetration of pile per blow of hammer
shall be checked taking an average of last 10 blows.
1115.1.3. The pile shoes which may be of

either cast iron conical type or mild steel flat type
shall have double reams for proper seating of the
removable casing tube inside the space between the
Page 854 of 1427

reams.
1115.1.4. Before commencement of pouring

of concrete, it shall be ensured that there is no
ingress of water in the casing tube from the
bottom. Further adequate control during withdrawal
of the casing tube is essential so as to maintain
sufficient head of concrete inside the casing tube at
all stages of withdrawal.
1115.1.5. Concrete in piles shall be cast

upto a minimum height of 600 mm above the
designed top level of pile, which shall be stripped off
at the time of construction of pile cap.
1115.2. Bored Cast-in-Situ Piles
1115.2.1. While concreting uncased

piles, voids in concrete shall be avoided and
sufficient head of concrete is to be maintained to
prevent inflow of soil or water into the concrete. It is
also necessary to take precautions during concreting
to minimise the softening of the soil by excess
water. Uncased cast-in-situ piles shall not be allowed
where mudflow conditions exist.
1115.2.2. The drilling mud such as bentonite

suspension shall be maintained at a level sufficiently
above the surrounding ground water level to ensure
the stability of the strata which is being penetrated
throughout the boring process until the pile has been
concreted.
Page 855 of 1427

1115.2.3. Where bentonite suspension is
used to maintain the stability of the bore-hole, it
is essential that the properties of the material
be carefully controlled at stages of mixing, supply
to the bore-hole and immediately before concrete is
placed. It is usual to limit :
i) The density of bentonite suspension

to 1.05 g/cc
ii) The marsh cone viscosity between 30
and 40
iii) The pH value between 9.5 and 12
iv) The silt content less than 1 per cent
v) The liquid limit of bentonite not less
than 400 per cent
These aspects shall act as controlling

factors for preventing contamination of bentonite
slurry for clay and silt.
1115.2.4. The bores shall be washed by

bentonite flushing to ensure clean bottom at two
stages viz. after completion of boring and prior to
concreting after placing of reinforcement cage.
Flushing of bentonite shall be done continuously
with fresh bentonite slurry till the consistency Of
inflowing and out-flowing slurry is similar.
1115.2.5. Tremie of 150 mm to 200 mm

diameter shall be used for concreting. The tremie
should have uniform and smooth cross-section
Page 856 of 1427

inside, and shall be withdrawn slowly ensuring
adequate height of concrete outside the tremie
pipe at all stages of withdrawal. Other
recommendations for tremie concreting are :
i) The sides of the bore-hole have to be

stable throughout.
ii) The tremie shall be water-tight
throughout its length and have a
hopper attached at its head by a
water-tight connection
iii) The tremie pipe shall be large enough
in relation to the sue of 20 mm
aggregate the tremie pipe shall be of
diameter not test for larger size
aggregate tremie pipe of larger
diameter is required
iv) The tremie pipe shall be lowered to
the bottom of the bore-hole, allowing
or drilling mud to rise inside it before
pouring concrete.
v) The tremie pipe shall always be kept
full of concrete and shall penetrate
well into the concrete in the bore-hole
with adequate margin of safely
against accidental withdrawal if the
pipe is surged to discharge the
concrete.
1115.2.6. For very long or large diameter

piles, use of retarding plasticiser in concrete is
desirable.
Page 857 of 1427

1115.2.7. For large diameter piles, it may
be essential to conduct non-destructive pile integrity
tests to evaluate integrity of the pile.
1115.2.8. Where possible, it may be

desirable to grout the base of pile with cement slurry
under suitable pressure after concrete in the pile
attains the desired strength. For this purpose, conduit
pipes with easily removable plugs at the bottom end
should be placed in the bore along with
reinforcement cage before concreting.
1116. TOLERANCES
1116.1. Permissible Tolerances for Pile
i) Precast Concrete Piles :

a. Variation in cross-sectional dimensions
: ± 5 mm
b. Variation in length :
c. Surface irregularities measured with 3 m
straight edge : 5 mm
d. Bow for length in mm
: Pile Length in
m
m
1
0
0
Page 858 of 1427

0
ii) Driven Piles
: +50 mm,
b. Variation from vertical or specified rake

: 1 in 50
c. Variation in the final position of the head
in plan : 75 mm
d. Variation of level of top of piles
: ± 25 mm
iii) Bored Piles
: +50 mm,
b. Variation from vertical or specified rake

: 1 in 50
c. Variation in the final position of the head
in plan : 50 mm
d. Variation of level of top of piles
Page 859 of 1427

: ± 25 mm
1116.2. Permissible Tolerances for Pile

Caps
(a) Variation in dimension

: +50 mm,
1
0
m
m
(b) Misplacement from specified position
in plan : 15 mm
(c) Surface irregularities measured with 3
m straight edge: 5 mm
(d) Variation of levels at the top
: ± 25 mm
1117. TESTS AND STANDARDS OF

ACCEPTANCE
The materials shall be tested in accordance

with these Specifications and shall meet the
prescribed criteria.
The work shall conform to these

Specifications and shall meet the prescribed
standards of acceptance.
1118. MEASUREMENTS FOR

PAYMENT
Page 860 of 1427

For supply of precast concrete, timber or
steel piles of specified cross-section, the
measurement shall be in metres of the length of piles
ordered in writing by the Engineer measured from
the head to the butt of the shoe or the tapered point.
Reinforcement in precast concrete piles shall not be
measured for payment.
For cast-in-situ driven and bored concrete

piles of specified cross-section, the measurement
shall be the length in metres of the accepted pile that
remains in the finished structure complete in place.
Reinforcement in cast-in-situ driven and bored
concrete piles shall be measured for payment as per
Section 1600.
Routine and Initial Pile Load Tests shall not

be measured for payment.
For installation of the pile, i.e. by driving in

the case, of precast concrete, timber, steel and cast-
in-situ driven piles, and by boring in the case of cast-
in-situ bored piles the measurement shall be the
length in metres that remains in the finished-
structure complete in place* limited to that shown on
drawings or ordered by the Engineer. No distinction
shall be made for penetration through hard strata or
rock and socketing into rock.
For steel liners/casing shown on the drawings

to be permanently left in place, the measurement
Page 861 of 1427

shall be by weight in tonnes that remains in the
finished structure complete in place, limited to that
shown on drawings or ordered by the Engineer.
For the pile cap, the quantity of concrete

shall be measured in cubic metres as per Section
1700. While reinforcement in pile cap
1119. RATE
The contract unit rate for supplying precast

concrete, umber or steel piles shall include cost of all
labour, materials, tools and equipment, and other
work involved in making or fabricating the pile
complete as shown on the drawing, and where
required its loading, transport, delivery to site
unloading and stacking it at the place indicated by
the Engineer. The cost of reinforcement as per
Section 1600 in precast concrete piles shall be
deemed to be included in the quoted rate for supply
of piles.
The contract unit rate for cast-in-situ driven

and. bored piles shall include the cost of concrete
and all other items as per Section 1700. The contract
unit rate shall also include costs of all labour,
materials, equipments and all other incidentals
involved in conducting routine and initial pile load
tests including installation of piles for initial load
tests. .
The contract unit rate for reinforcement in
cast-in-situ driven and bored piles shall be as per
Page 862 of 1427

Section 1600.
The contract unit rate for installation of piles

shall include full compensation for furnishing all
labour, materials, tools and equipment, and
incidentals for doing all the works involved in
driving limber, precast concrete and steel piles,
driving or making bores for cast-in-situ driven and
bored concrete piles, culling off pile heads, all
complete in place to the specified penetration of
piles. Providing temporary liner/casing and its
withdrawal and placing reinforcement in position
shall also be deemed 10 be included in the rate for
installation of piles and no additional payment shall
be made for the same.
The contract unit rate for permanent steel

liners shall include cost of all labour, fabrication and
placing the steel liner to the required depth as shown
on the drawings and as ordered by the Engineer.
The contract unit rate for concrete in pile cap

shall cover all costs of labour, materials, tools, plant
and equipment, formwork and staging including
placing in position, sampling and testing and
supervision, all as per Section 1700 Reinforcement
in the pile cap shall be paid for separately as per
Section 1600
Page 863 of 1427

Well Foundations
1200
Well Foundations
Page 864 of 1427

1201. DESCRIPTION
This work consists of construction of well

foundation, taking it down to the founding level
through all kinds of sub-strata, plugging the bottom,
filling the inside of the well, plugging the top and
providing a well cap in accordance with the details
shown on the drawing and as per these
specifications, or as directed by the Engineer.
In case of well foundations of size larger than

12 m diameter, supplemental construction
specifications will be necessary.
1202. GENERAL
1202.1. Wells may have a circular,

rectangular, or D-shape in plan and may consist of
one, two or more compartments in plan. The outer
wall of the well is known as well steining which
may be cellular.
The process of taking down the web to the

founding level is known as well sinking. After
reaching the founding level, the hollow inside the
well, (“dredge hole”) is plugged at the bottom by
concrete , (“bottom plug”). The dredge hole is then
Filled with approved filling upto the level indicated
on the drawings and provided with a concrete plug
(“top plug”).
To facilitate sinking of well, steel cutting
Page 865 of 1427

edge is fabricated and, connected to a concrete well
curb of required shape. On top of the well curb,
adequate height of well steining is cast and the
process of sinking is carried out. After a portion of
the well has been sunk, another height of well
steining is cast on top of the previous section, and
further sinking carried out. This process is continued
till the bottom level of the well reaches the
founding level.
At the top of the well steining, an adequately

designed “well cap” is laid which transmits the loads
and forces from the sub-structure (piers or
abutments) to the foundations.
1202.2. At least one bore-hole must be

available/carried out in accordance with these
specifications at each well foundation location,
•prior to commencement of work. The depth of bore-
holes should extend upto, a depth equal to one and a
half times the outer diameter/least dimension of the
well below the anticipated founding level. The
results ,of soil exploration should be presented in
accordance with clause of IRC:78. In case the well
foundation is to rest on a rocky strata, kit may be
necessary to undertake additional borings /probings
prior to commencement of work to ascertain the
actual profile and the quality of the rocky strata, at
the level at which the well has to be seated, etc.
1202.3. Blasting may have to be resorted to

in order to facilitate sinking through difficult strata,
Page 866 of 1427

such as boulders and rocks etc. In case blasting is
anticipated, protective/strengthening measures
specified in clause 710.6 (IV) of IRC:78 shall be
taken. The grade of concrete in bottom 3 metres of
steining shall not be leaner than M 20 or as shown
on the drawings.
1202.4. In case the bore hole data shows the

presence of steeply dipping rock, chiselling may
have to be resorted to so as to obtain proper seating
of the foundation. For this purpose, the well may
require to be dewatered completely under high air
pressure inside the well. This process is known as
pneumatic sinking. Pneumatic sinking may also have
to be resorted to in cases where obstacles such as
tree trunks, large sized boulders or hard strata etc.
cannot be removed by open dredging. The necessity
of adopting pneumatic sinking shall be decided by
the Engineer.
‘ The curb and steining have to be
specifically designed for special loading* when
pneumatic sinking is adopted.
1203. SETTING OUT AND

PREPARATIONS FOR SINKING
1203.l. Necessary reference points shall be

fixed, away from the zone of blow-ups or possible
settlements resulting from well sinking , operations.
Such reference points shall be connected to the
permanent the odolite stations with the base line on
the banks. The centre of the individual wells shall be
Page 867 of 1427

marked with reference to these stations. The
distance, wherever practicable, shall be checked with
the help of accurate tapes and precision distomat.
Reference points shall also be fixed to mark

X-X axis (usually traffic direction) and Y-Y axis
(normal to X-X axis) accurately.
A temporary bench mark shall also be

established near the well foundation, away from the
zones-of blow-ups or possible settlement. The bench
mark shall be checked regularly with respect to the
permanent bench mark established at the bridge site.
1203.2. For wells which are to be pitched in

water, an earthen or sand island shall be constructed.
Sand islands are practicable for water depths of
about 5 metres under stable bed soil conditions. For
greater depths or in fast flowing rivers or for
locations where soil is too weak to sustain sand
island, floating caissons may have to be adopted.
The plan dimensions of sand islands shall be

such as to have a working space of at least 2 metres
all around the steining. The dimension of the sand
islands shall however be not less than twice the
dimension in plan of the well or caisson. Sand
islands shall be maintained to perform their
functions, until the well is sunk to a depth below the
bed level at least equal to the depth of water.
Sand island shall be protected against scour
Page 868 of 1427

and the top level shall be sufficiently above the
prevailing water level to be decided by the Engineer
so that it is safe against wave action.
While sand islands are constructed at well

location, floating caissons are generally fabricated at
or near the banks on dry land or dry docks. Floating
caissons are towed into position in floating
condition.
Floating caissons may be of steel, reinforced

concrete or a combination of the two. They should
have at least 1.5 m free board above water level and
increased, if considered necessary, in case there is a
possibility of caissons sinking suddenly owing to
reasons such as scour likely to result from the
lowering of caissons, effect of waves, sinking in very
soft strata etc.
Stability of floating caissons shall be ensured
against overturning and capsizing while being towed
and during sinking for the action of water current,
wave pressure, wind etc.
For floating caissons, a detailed method

statement for fabrication, floating and sinking of
caissons shall be prepared and furnished to I’’ the
Engineer. Such statement shall include the total
tonnage of steel involved, fabrication and welding
specifications, list of materials and plant and a
description of operations and manpower required for
the work. The caisson shall be tested for leakages
before being towed to site.
Page 869 of 1427

1203-3. Equipment
Equipment shall be deployed for construction

of well foundation |j as required and as directed by
the Engineer. Generally, the following ;’ equipments
may be required for the work :
(a) Crane with grab buckets - capacity 0.5

to 2.0 cum.
(b) Submersible pumps
(c) Air compressors, air leeks and other
accessories where pneumatic sinking
of well is anticipated.
(d) Chisels of appropriate sizes
(e) Aqua-header for cutting rocky strata
(f) Diving helmets and accessories
(g) Equipment for concrete production,
transportation planing and compaction
1204. CUTTING EDGE
1204.1. The mild steel cutting edge shall be

made from structural steel sections. The cutting edge
shall weigh not less than 40 kg per metre length-and
be properly anchored into the well curb, as shown in
the drawing.
When there are two or more compartments in

a well, the bottom end of the cutting edge of the
inner walls of such wells shall be kept at about 300
mm above that of outer walls.
Page 870 of 1427

1204.2. The parts of cutting edge shall be
erected on level firm ground. Temporary supports
shall be provided to facilitate erection and
maintaining the assembly in true shape. The
fabrication may be carried out in the shop or at site.
Steel sections shall not be heated and forced into
shape. However, “V” cuts may be made in the
horizontal portion, uniformly throughout the length,
to facilitate cold bending. After bending, such “V”
cuts should be closed by welding. Joints in the
lengths of structural sections, unless otherwise
specified shall be fillet welded using single cover
plate to ensure the requisite strength of the original
section.
12043. The cutting edge shall be laid about

300 mm above .prevalent water level.
1205. WELL CURB
1205.1. The well curb may be precast or cast-

in-situ. Steel formwork for well curb shall be
fabricated strictly in conformity with the drawing.
The outer face of the curb shall be vertical. Steel
reinforcements shall be assembled as shown on the
drawings. The bottom ends of vertical bond rods of
steining shall be fixed securely to the cutting edge
with check nuts or by welds.
The formwork on outer face of curb may be

removed within 24 hours after concreting. The
Page 871 of 1427

formwork on inner face shall be removed after 72
hours.
1205.2. All concreting in the well curb

shall be done in one continuous operation.
1206. WELL STEINING
1206.1. The dimensions, shape, concrete

strength and reinforcements of the well shall strictly
conform to those shown on the drawings. The form
work shall preferably be of M.S. sheets shaped and
stiffened suitably. In case timber forms are used,
they shall be lined with plywood or M.S. sheets.
1206.2. Steining built in the first lift above

the well curb shall not be more than 2 metres and in
subsequent lifts it shall not exceed the diameter of
the well or the depth of well sunk below the
adjoining bed level at any time. For stability, the first
lift of steining shall be cast only after sinking the
curb at’ least partially for stability. Concreting of
steining may be carried out in subsequent lifts of
about 2 to 2.5 metres. .Attempts should be made to
minimise the number of construction joints. The
concreting layers shall be limited to about 450mm
restricting the free fall of concrete to not more than
1.5 m. Laitance formed at the top surface of a lift
shall be removed to expose coarse aggregates before
setting of concrete at the proposed construction joint.
As far as possible, construction joints shall not be
kept at the location of laps in the vertical steining
Page 872 of 1427

bars.
1206.3. The steining of the well shall be

built in one straight line from bottom to top such
that if the well is tilted, the next lift of steining will
be aligned in the direction of the tilt. The work will
be checked carefully with the aid of straight edges of
lengths approved by the Engineer. Plumb bob or
spirit level shall not be used for alignment. After
sinking of a stage is complete, damaged portions if
any, of steining at top of the previous stage shall be
properly repaired before constructing the next stage.
1206.4. The height of steining shall be

calibrated by making at least 4 gauges (preferably in
traffic direction and in a direction normal to traffic
direction) distributed equally on the outer periphery
of the well each in the form of a 100 mm wide strip
painted on the well, with every metre mark shown in
black paint. The. gauges shall start with zero at the
bottom of the cutting edge. Marking of the gauges
shall be done carefully with a steel tape.
1206.5. After reaching the founding level,

the well steining shall be inspected to check for any
damage or cracks. The Engineer will direct and the
Contractor shall execute the remedial measures
before acceptance of the well steining. In case the
well cannot be accepted even with any remedial
measures, then the well shall stand rejected.
207. WELL SINKING
Page 873 of 1427

1207.1. General
The well shall as far as possible be sunk true

and vertical through all types of strata.
Sinking or loading of the well with Kent
ledge shall be commenced only after the steining has
been cured for at least 48 hours or as specified in the
drawings.
No well shall be permitted to be placed in a

pre-dredged hole.
The well shall be sunk by excavating

material uniformly from inside the dredge hole. Use
of water jetting, explosives and divers may be
adopted for sinking of wells through difficult strata
with prior approval of the Engineer.
Normally dewatering of well should not be

permitted as a means for sinking the well. It also
shall never be resorted to if there is any danger of
sand blowing under the well. Dewatering shall
however be done when well is to be founded into
rock. Pneumatic sinking may have to be resorted to
where obstacles such as tree trunks, large size
boulders, etc. are met at the bottom or when there is
hard strata which cannot be removed by open
dredging. The necessity for pneumatic sinking shall
be decided by the Engineer.
Sinking history of well shall be maintained in
Page 874 of 1427

the format given in Appendix 1200/1.
1207.2. Use of Kentledge as Sinking Load
Kentledge shall be placed in an orderly and
safe manner on the loading platform and in such a
way that it does not interfere with the excavation of
the material from inside the dredge hole and also
does not in any way damage the steining of the well.
Where tilts are present or there is a danger of

well developing a tilt, the position of the load shall
be regulated in such a manner as to provide greater
sinking effort on the higher side of the well..
1207.3. Use of Water Jetting
Water jetting may be employed for well

sinking wherever necessary.
1207.4. Use of Explosives

Mild explosive charges may be used as an aid
for sinking of the well only with prior permission of
the Engineer. Blasting of any sort shall only be done
in the presence of the Engineer and not before the
concrete in the steining has hardened sufficiently and
is more than 7 days old. When likelihood of blasting
is predicted in advance, protection of the bottom
portion of the well shall be done as per these
specifications. After blasting operations are
completed, the well curb and steining shot Id be
examined for any cracks and remedial measures
taken.
Page 875 of 1427

If blasting has been used after the well has
reached the design foundation level, normally 24
hours shall be allowed to lapse before the bottom
plug is laid.
The charges shall be exploded well below the

cutting edge by making a sump so as to avoid
chances of any damage to the curb or to the steining
of the well. A minimum sump of 1 metre depth
should be made before resorting to blasting. Use of
large charges, 0.7 kg or above, may not be allowed
except under expert direction and with the
permission from the Engineer. Suitable pattern of
charges may be arranged with delay detonators to
reduce the number of charges fired at a time. The
burden of the charge may be limited to 1 metre and
the spacing of holes may normally be kept as 0.5 to
0.6 metres.
All prevalent laws concerning handling,

storing and using of explosives shall be strictly
followed.
All safety precautions shall be taken as per

IS:4081 “Safety Code for Blasting and related
Drilling Operations”, to the extent applicable,
whenever blasting is resorted to.
There should be no equipment inside the well

nor shall there be any labour in the close vicinity of
the well at the time of exploding the charges.
Page 876 of 1427

If rock blasting is to be done for seating of
the well, the damage caused by flying debris should
be minimised by covering blasting holes by rubber
mats before blasting.
1207.5. Use of Divers
Use of divers may be made both for sinking

purpose like removal of obstructions, rock blasting
and for inspection. All safety precautions shall be
taken as per any acceptable safety code for sinking
with divers or any statutory regulations in force.
Only persons trained for the diving operation

shall be employed and shall be certified to be fit for
diving by an approved doctor.
They shall work under expert supervision.

The diving and other equipments shall be of
acceptable standard and certified to this effect by an
approved independent agency, It shall be well
maintained-for safe use.
Arrangement for ample supply of low

pressure clean cool air shall be ensured through an
armoured flexible hose pipe. Standby compressor
plant shall be provided in case of breakdown.
Separate high pressure connection for use of

pneumatic tools shall be made. Electric lights where
provided shall be at 50 volts (maximum). The raising
of the diver from the bottom of wells shall be
Page 877 of 1427

controlled so that decompression rate conforms to
the rate as laid down in appropriate regulations.
1207.6. Use of Pneumatic Sinking
1207.6.1. General
The Engineer shall familiarise himself with

particular reference to caisson diseases and working
of the medical air-lock. A doctor competent to deal
with cases of “Caisson Diseases” or other compli-
cations arising as a result of working under high
pressure,* shall be stationed at the construction site
when pneumatic sinking is under progress.
The contractor shall provide complete

facilities including the issuing of orders to ensure
strict enforcement of the requirements outlined in
Safety provisions as contained in IS:4138 and

in these specifications shall be strictly followed.
Pneumatic sinking shall be restricted to a

depth of 30.0 m.
1207.6.2. Man-Locks and Shafts
Locks, reducers, and shaft used in connection

with caissons shall be of riveted construction
throughout. The material used in their manufacture
shall be steel plate with thickness not less than 6
Page 878 of 1427

mm.
Shafts shall be subjected to hydrostatic or air

pressure test of at least 0.5 MPa, at which pressure
they shall be tight. The pressure at which testing has
been done shall be clearly and visibly displayed.
Shafts shall be provided, with a safe, proper

and suitable staircase for its entire length including
landing platforms which are not more than 6 metres
apart. Where this is impracticable due to space
constraint, suitable ladders along with landing
platforms shall be installed. These shall be kept clear
and in good condition at all times and shall be
constructed, inspected and maintained to the entire
A 1.0 m wide platform with 1.0 m high

railing shall be provided all round the caisson air
locks.
Where 15 or more men are employed,

caissons shall have two locks, one of which shall be
used as a man lock.
Locks shall be located so that the lowest part

of the bottom door shall not be less than 1 metre
above high water level.
The supply of fresh air to the working

chamber shall at all times be sufficient to permit
work to be done without any danger or excessive
Page 879 of 1427

discomfort. All air supply lines shall be supplied
with check valves and carried as near to the face as
practicable.
A man-lock shall be used solely for the

compression or decompression of persons, and not
for the passage of plant and material and shall be
maintained in a reasonably clean and sufficiently
warm state. However, any hand tool or hand
instruments used for the purpose of the work may be
carried into the man-lock.
Where it is not reasonably practicable to

provide a separate man-tock for use by persons only,
the lock when it is in actual use for compression or
decompression of a person or persons shall not be
put, simultaneously, to any other use and shall be in
a reasonably clean and sufficiently warm state.
1207.6.3. Valves
Exhaust valves shall be provided, having

risers extending to the upper part of the chamber.
These shall be operated, whenever necessary
specially after a blast. Precautions shall be taken that
men are not allowed to resume work after a blast -
until the gas and smoke are cleared.
1207.6.4. Medical supervision and

certification
Every employee absent from work for 10 or
Page 880 of 1427

more consecutive days due to illness or any other
disability shall be required to pass the regular
physical examination by the doctor before being
permitted to return to work.
After a person has been employed

continuously in compressed air for a period of 2
months, he shall be re-examined by the doctor and
shall not to be permitted to work until such re-
examination has been made and the report is
satisfactory.
No person known to be addicted to the

excessive use of intoxicants shall be permitted to
work in compressed air.
The doctor shall, at al’ times, keep a

complete and full record of examinations made by
him, which shall contain dates of examinations, a
clear and full description of the person examined, his
age and physical condition at the lime of
examination and a statement as to the period such a
person has been engaged in such employment
Records shall be kept at the place where the work is
in progress and shall be subject to inspection by
authorised officers.
Every man lock shall always have a doctor or

a responsible person in attendance. In case the
person in charge is not a doctor he must have
positive means of promptly communicating with and
securing the services of a competent doctor in case
Page 881 of 1427

of emergency. Such arrangements shall invariably be
subject to the approval of the Engineer.
If the air pressure exceeds 0.2 MPa gauge or

if 50 or more men are employed, it is obligatory for
the person in charge of medical lock to be a doctor
experienced in this type of work.
All cases of compressed-air illness shall be

reported and copies of all such reports shall be kept
on file at the place of work.
1207.6.5. Lighting
All lighting in compressed air chambers shall

be operated only by electricity. Two independent
electric lighting systems with independent sources of
supply shall be used. These shall be so arranged that
the emergency source shall become automatically
operative in case of failure of the regularly used
source.
The minimum intensity of light on any

walkway ladder, stairway, or lower working level
shall be one-quarter (1/4) candlepower. In all work
places, the lighting shall always be such as to enable
workmen to see their way about clearly. All external
parts of lighting fixtures and electrical equipment
lying within 2.5 metres above the floor shall be
constructed of non-combustible, non-absorbing
insulating materials. If metal is used it must be
effectively earthed. Portable lamp shall have non-
Page 882 of 1427

combustible, non-absorbing insulating sockets,
approved handles, basket guards and approved
cables. The use of worn or defective portable and
pendant conductors, shall be prohibited.
1207.6.6. Safety against fire hazard
No oil, gasoline, or other combustible

material shall be stored within 30 metres of any
shaft, caisson, or tunnel opening. However, oil may
be stored in suitable tanks in isolated fireproof
buildings, provided such buildings are not less than
IS metres from any shaft, caisson, or tunnel opening
or any building directly connected thereto.
Positive means shall be taken to prevent

leaking flammable liquids from flowing into areas
specifically mentioned in the preceding paragraph.
Where feasible, a fire hose connected to a

suitable source of water shall be provided at the top
of every caisson. Where fire mains are not
accessible, a supply of water shall be stored in tanks
near the top of every caisson, provided fire pails or
suitable pumps are kept available. Approved fire
extinguishers shall also be provided.
1207.6.7. Sanitation
Properly heated, lighted and ventilated

dressing rooms shall be provided for all employees
engaged in compressed air work. Such rooms shall
Page 883 of 1427

contain lockers and benches and be open and
accessible to men during intermission between
shifts. Adequate toilet accommodation of one for
every twenty five employees shall be provided.
Care shall be taken to keep all parts of the

caissons and other working compartments, including
locker rooms, dry rooms, rest rooms, and other
equipment in a good sanitary condition and free from
refuse, decaying, or other objectionable matter.
No nuisance shall be tolerated in the air

chamber. Smoking shall be strictly prohibited and all
matches and smoking materials shall be left out of
the locker rooms.
A separate dry-room shall be provided where

working clothes may be dried within reasonable
time.
1207.6.8. Protection against gases
In all cases where gas is expected including

alluvium impregnated with decayed vegetable matter
the use of Davy Safety Lamp shall be compulsory.
1207.6.9. Additional safety provisions
a) The weight of the pneumatic platform

and that of steining and kentledge, if
any, shall be sufficient to resist the
uplift from air inside, skin friction
Page 884 of 1427

being neglected in this case. If, at any
section the total weight acting
downwards is less than the uplift
pressure of air inside, additional
kentledge shall be placed on the well.
If it is not possible to make the well
heavy enough during excavation,
“blowing down” may be used. The men
should be withdrawn and air pressure
“reduced The well should then begin to
move with small reduction in air
pressure. “Blowing down” should only
be used when the ground is such that it
will not heave up inside the chamber
when the pressure is reduced. When the
well does not move with the reduction
in air pressure, kentledge should be
added. “Blowing down” should be in
short stages and the drop should not
exceed. 0.5 metre at any stage. To
control sinking during blowing down,
use of packings are recommended.
b) The pneumatic sinking plant and other
allied machinery shall not only be of
proper design and make, but also shall
be worked by competent and well
trained personnel. Every pan of the
machinery and its fixtures shall be
minutely examined before installation
and use. Availability of appropriate
spares, standbys, safety, of personnel as
recommended in IS:4 138 for working
Page 885 of 1427

in compressed air must be ensured at
site. Codes for safety and for working
in compressed air and other labour laws
and practices prevalent in the country,
as specified to provide safe, efficient
and expeditious sinking shall be
followed.
c) Inflammable materials shall not be
taken into air locks and smoking shall
be prohibited. Wherever gases are
suspected to be issuing out of dredge
hole, the same shall be analysed by
trained personnel and necessary
precautions adopted to avoid hazard to
life and equipment.
d) Where blasting is resorted to, it shall be
carefully controlled and all precautions
regarding blasting shall be observed.
Workers shall be allowed inside after
blasting only when a competent and
qualified person has examined the
chamber and steining thoroughly and
found the same to be safe.
1207.7. Precautions During Sinking
a) When the wells have to be sunk close to

etch other and clear distance between
them is not greater than the diameter of
wells, sinking shall be sunk up on all
wells and they shall he sunk alternately
to that sinking of wells proceeds
Page 886 of 1427

uniformly. Simultaneous and even
dredging shall be carried out in the
wells in such a manner that the
difference in the levels of the sump and
cutting edge in the adjacent wells does
not exceed half the clear gap between
them. Plugging of all the wells shall be
done together.
b) During sinking of dumb-bell or double

D-shaped wells, the excavation in both
the dredge holes should be carried out
simultaneously and equally.
c) Bore chart shall be referred to

constantly during sinking for taking
adequate care while piercing different
types of strata. The type of soil as
obtained during the well sinking should
be compared with bore chin so as to
take prompt decisions.
d) Before seasonal Hoods all wells on

which sinking is in progress shall be
sunk to sufficient depths below the
designed scour level. Further, they shall
be temporarily filled and plugged so
that they do not suffer v\y tilt or shift
during the floods.
e) All necessary precautions shall be

taken against any possible damage to
Page 887 of 1427

the foundations of existing structures in
the vicinity of the wells, prior to
commencement’ of dredging from
inside the well.
f) The dredged material shall riot be

allowed to accumulate over the well. It
shall be dumped and spread, as far
away as possible, and then continuously
and simultaneously removed, as
directed by the Engineer. In case the
river stream flows along one edge of
the well being sunk, the dredged
material shall not be dumped on the
dry side of the bank* but on the side
on which the river current flows.
g) Very deep sump shall not be made

below the well curb, as it entails risk
of jumping (sudden sinking) of the
well. The depth of sump shall be
generally limited to one-sixth of the
outer diameter/least lateral dimension
of the well in plan. Normally, the depth
of sump shall not exceed 3.0 metres
below the level of the cutting edge
unless otherwise specifically permitted
by the Engineer.
h) In case a well sinks suddenly with a

jerk, the steining of the well shall be
examined to the satisfaction of the
Page 888 of 1427

Engineer to see that no damage has
occurred to it.
i) In pneumatic sinking, the well shall not,

at any time, be dropped to a depth
greater than 500 mm by the method of
“blowing down”.
j) Dewatering shall be avoided if sand

blows are expected. Any equipment and
men working inside the well shall be
brought out of the well as soon as there
are any indications of s sand-blow.
k) Sand blowing in wells can often be

minimised by keeping the level of
water inside the well higher than the
water table and also by adding heavy
kentledge.
l) In soft strata prone to settlement/creep,

the construction of the abutment wells
shall be taken up only alter the
approach embankment for a sufficient
distance near the abutment has been
completed.
1207.8. Tilts and Shifts
The inclination of the well from the vertical

is known as tilt and the horizontal displacement of
Page 889 of 1427

the centre of the well at the founding level from its
theoretical position is known as shift.
Unless otherwise specified, the tilt of any

well shall not exceed 1 (horizontal) in 80 (vertical),
and the shift at the well base shall not be more than
150 mm in any resultant direction.
Tilts and shifts shall be carefully checked and
recorded in the format vide Appendix 7200/77
regularly during sinking operations. For the purpose
of measuring the tilts along the two axes of the
bridge, reduced level of the marks painted on the
surface of the steining of the well shall be taken. For
determination of shift, locations of the ends of the
two diameters shall be precisely measured along the
two axes, with reference to fixed reference points.
Whenever any lilt is noticed, adequate

preventive measures like placing eccentric
kentledge, pulling, strutting, anchoring or dredging
unevenly and depositing dredge material unequally,
putting obstacles below cutting edge. Water jetting
etc., shall be adopted before any further sinking.
After correction, the dredged material shall be spread
out uniformly.
A pair of wells close to each other have a

tendency to come closer while sinking. Timber struts
may be introduced in between the steining of these
wells to prevent tilting.
Tilts occurring in a well during sinking in
Page 890 of 1427

dipping rocky strata can be safeguarded by suitably
supporting the curb.
In the event of a well developing tilt or shift

beyond the specified permissible values, the
Contractor shall have to carry out, :at his own cost,
suitable remedial measures to the satisfaction of the
Engineer, to bring the till and shift within
permissible values, as far as practicable.
If the resultant till and / or shift of any well

exceeds the specified permissible values, generally it
should not exceed 1 in 50 and 300 mm respectively.
The well so sunk shall be regarded as not
conforming to specifications and a sub-standard
work. The Engineer in his sole discretion, may
consider accepting such a well, provided :
(i.) Calculations for foundation pressures and

steining stresses, accounting for the actual tilt
and shift furnished by the Contractor show
that the well is safe. Any remedial measures
required to bring the stresses within
permissible values (such as increase in the
dimension of the well cap, provision of
dummy weights on the well cap etc), shall be
carried out by the Contractor without.
claiming for any extra cost.
(ii.) The Contractor shall agree to reduction in
rates in accordance with Clause 1215(g).
In case the Engineer, in his discretion, rejects
Page 891 of 1427

the well, the Contractor shall dismantle the rejected
well to the extent directed by the Engineer and
remove the debris. Further, the Contractor shall, at
his own risk and expense complete the bridge with
modified span arrangement acceptable to the
Engineer.
1207.9. Seating of Wells
The well shall be uniformly seated at the

founding strata. It shall be ensured by test borings
that the properties of the soil encountered at the
founding strata and upto a depth of one and a half
times the •well diameter is identical to that adopted
in the design. The procedure for lest borings shall
satisfy the provisions of these specifications. In case
the soil encountered is inferior to that adopted in
design, the well shall be re-designed by the Engineer
adopting the soil properties actually encountered and
the founding level intimated to the Contractor, who
shall carry out the work.
In case of seating of wells in hard rocky

strata, where the rock profile is steeply sloping,
pneumatic methods of sinking may be adopted to
seat the well evenly as directed by the Engineer. The
decision of adopting pneumatic sinking shall be
taken by the Engineer. The cutting edge may also be
embedded for a suitable depth in the rocky strata, as
decided by the Engineer keeping in view the quality
of rock. As an additional measure of safety, the well
shall be anchored to the rocky strata by anchor bars
Page 892 of 1427

provided in the steining of the well, as shown on the
drawing irrespective of the fact that tension develops
or not at the base of the well under design loads.
After the well has been evenly seated on good hard
rock, arrangements shall be made to facilitate proper
inspection in dry and visible conditions before the
bottom plug is laid.
1208. BOTTOM PLUG
For bottom plug, the concrete mix shall be

designed (in dry condition) to attain the concrete
strength as mentioned on the drawing and shall
contain 10 per cent more cement than .that required
for the same mix placed dry, to cater for underwater
concreting. However, the total cement content shall
not be less than 363 kg/cu.m. of concrete with a
slump in the range of 150 mm to 200 mm.
Admixtures may be added to the concrete to impart
the required characteristics indicated herein.
Concrete for the bottom plug shall be laid by

tremie pipe method. Tremie concrete when started
shall be continued without interruption for full
concreting in the bottom plug. The concrete
production equipment and placement equipment
should be sufficient to enable under water concreting
within stipulated time. Necessary standby equipment
should be available for emergency situation.
Before commencing plugging, all loose

material from the bottom of the well shall be
Page 893 of 1427

removed.
Concreting shall be done in one continuous

operation till the dredge hole is filled upto the
required height and thereafter sounding shall be
taken upto ensure that the concrete has been laid to
the required height.
Least disturbance shall be caused to the water

inside the well while laying concrete in the bottom
plug.
Concrete shall not be disturbed in any way

for at least 14 days.
In order to check any rise in the level of the

bottom plug soundings should be taken at the close
of concreting and once every day for the subsequent
3 days.
The soundness of the bottom plug may be

tested by dewatering the well by 5 metres below the
surrounding water level and checking the rise of
water. The rate of rise shall preferably be less than
10 cms per hour. In case the rate is higher, suitable
remedial measures as directed by the Engineer, shall
be taken by the Contractor at his own cost.
1209. SAND FILLING
Sand filling shall commence after a period of

3 days of laying of bottom plug. Also, the height of
Page 894 of 1427

the bottom plug shall be verified before starting sand
filling.
Sand shall be clean and free from earth, clay

clods, roots, boulders, shingles, etc. and shall be
compacted as directed. Sand filling shall be carried
out upto the level shown on the drawing, or as
1210. TOP PLUG
After filling sand upto the required level a

plug of concrete shall be provided over it as shown
on the drawing, or as directed by the Engineer.
1211. WELL CAP
A reinforced cement concrete well cap will

be provided over the top of the steining in
accordance with the drawing. Formwork will be
prepared conforming to the shape of well cap.
Concreting shall be carried out in dry condition. A
properly designed false steining may be provided
where possible to ensure that the well cap is laid in
dry conditions.
The bottom of the well cap shall be laid

preferably as low as possible, taking account the
water level prevalent at the time of casting
Bond rods of steining shall be anchored into

the well cap.
Page 895 of 1427

1212. TOLERANCES
The permissible tilt and shift shall not exceed

1 (horizontal) in 80 vertical) and the shift at the well
base shall not be more than 150 £ mm in any
resultant direction.
For the well steining and well cap the
permissible tolerances shall he as follows :
(a) Variation in dimension

: +50 mm - 10 mm
(b) Misplacement from specified position
in plan : 15 mm
(c) Surface irregularities measured with 3
m straight edge : 5 mm
(d) Variation of levels at the top
: ±25 mm

ACCEPTANCE



PAYMENT
Page 896 of 1427

All quantities shall be measured from the
drawing, or as ordered by the Engineer, excepting
those required to be provided by the Contractor at
his cost.
a) The cutting edge shall be measured in
tonnes based on the net weight of metal
used in it, as per Section 1900.
b) The concrete in curb, well steining and
well cap shall be measured in cubit
metres in each of the Kerns as per
Section 1700. The reinforcements shall
be measured in tonnes separately in each
of the items, as per Section 1600.
c) The measurement for well sinking shall
be made in running metres for
different depths and in different types of
strata (for example, predominantly sand/
clay soil, soft rock, hard rock, etc) as
specified in the Contract The depth of
sinking shall be measured from the
level specified in the Contract. If no
level has been specified in the Contract,
sinking shall be measured from the low
water level or from the level at which the
cutting edge was laid, whichever is
higher.
d) The quantity of concrete, in bottom
and top plug shall be measured in
cubic metres as per Section 1700.
e) The quantity of sand filling shall be
measured in cubic metres.
Page 897 of 1427

f) Pneumatic sinking, where required
shall be paid as a separate item and
shall be measured in cubic metres of
material to be excavated.
1215. RATE
a) The Contract unit rates of cutting edge

shall cover all costs of labour, material,
tools, plant and equipment, including
placing in position, sampling and testing,
and, supervision, ill as per respective
Section of Structural Sled Work and
as described in this section.
b) The Contract unit rates for concrete in
curb, steining, bottom plug, top plug
and well cap. shall cover all costs of
labour, material, tools, plant and
equipment, formwork and staging
including placing in position, sampling
and testing, and, supervision, all as per
respective Section of Structural
Concrete and as described in this section.
c) The Contract unit rates for reinforcement
in curb, steining, and well cap, shall
coverall cost? of labour, material, tools,
plant and equipment, including bending
to shape, placing in position,
sampling, testing and supervision,
al! as per respective Section of Steel
Reinforcement and as described in this
section.
Page 898 of 1427

d) The Contract unit rate! for sand filling
shall cover all costs of labour, material,
tools, plant and equipment, including
placing in position, sampling, testing and
supervision, all as described in this
section.
e) The Concrete unit rates for sinking shall
cover, the cost of labour, tools, and
equipment and plant and for all
operations and other incidental for
sinking of well including seating
excepting provisions of pneumatic
sinking as described in this Section. The
unit rates shall specify the strata such as
types of soil, rock, etc. The rate shall
cover all testing and supervision
required for the work.
f) The Contract unit rate of material to be
excavated by pneumatic sinking shall
cover all costs of labour, material, tools,
plant and other equipment and other
incidentals and safely provisions and
supervision required for pneumatic
sinking as per this Section.
g) Reduction in contract unit rates for
sinking as a penalty, in pursuance of
clause 1207.8.
If any well with tilt arid/or shift exceeding

beyond permissible values is accepted by the
Engineer, the Contractor shall give a reduction in the
rates as follows :
Page 899 of 1427

S. Amount of tilt and/or shift Per cent
No. deduction. on
the rate(s)
for sinking of
whole well
1. Tilt exceeding the specified 5 per cent
permissible value but equal
to or within 1 in 60
2. Tilt exceeding 1 in 60 but 10 per cent
equal to or within 1 in 50
3. Tilt exceeding 1 in 50 20 per cent
4. Shift exceeding the specified 2 per cent
permissible value but equal
to or within 200 mm
5. Shift exceeding 200 mm but 5 per cent
equal to or within 300 mm
6. Shift exceeding 300 mm 10 per cent
Penalties for excessive tilt and shift shall be

deducted separately
Page 900 of 1427

Brick Masonry
1300
Brick Masonry
Page 901 of 1427

1301. DESCRIPTION
This work shall consist of construction of

structures with bricks jointed together by cement
mortar in accordance with the details shown oh the
drawings or as approved by the Engineer.
1302. MATERIALS
All materials to be used in the work shall

conform to the requirements laid down in Section
1000.
1303. PERSONNEL
Only trained personnel shall be employed for

construction and supervision.
1304. CEMENT MORTAR
Cement and sand shall be mixed in specified

proportions given in the drawings. Cement shall be
proportioned by weight, taking the unit weight of
cement as 1.44 tonne per cubic metre. Sand shall be
proportioned by volume taking into account due
allowance for bulking. All mortar shall be mixed
with a minimum quantity of water to produce desired
workability consistent with maximum density of
mortar. The mix shall be clean and free from
injurious type of soil/acid/alkali/ organic matter or
deleterious substances.
Page 902 of 1427

The mixing shall preferably be done in
a mechanical mixer operated manually or by
power. Hand mixing can be resorted to as long as
uniform density of the mix and its strength are
assured subject to prior approval of the
Engineer. Where permitted, specific permission
is to be given by the Engineer. Hand mixing
operation shall be carried out on a clean water-tight
platform, where cement and sand shall be first
mixed dry in the required proportion by being turned
over and over, backwards and forwards several
times till the mixture, is of uniform colour.
Thereafter, minimum quantity of water shall be,
added to bring the mortar to the consistency of a stiff
paste. The mortar shall be mixed for at least two
minutes after addition of water.
Mortar shall be mixed only in such quantity

as required for Immediate use. The mix which has
developed initial set shall not be used. Initial set of
mortar with ordinary Portland Cement shall ,
normally be considered to have taken place in 30
minutes after mixing. In case the mortar has
stiffened during initial setting time because of
evaporation of water, the. same can be re-tempered
by adding water as frequently as needed to restore
the requisite consistency, but this re-tempering shall
not be permitted after 30 minutes. Mortar unused for
more than 30 minutes shall be rejected and removed
from site of work.
1305. SOAKING OF BRICKS
Page 903 of 1427

All bricks shall be thoroughly soaked in a
tank filled with water for a minimum period of one
hour prior to being laid. Soaked bricks shall be
removed from the tank sufficiently in advance so
that they are skin dry at the time of actual laying.
Such soaked bricks shall be stacked on a clean place
where they are not contaminated with din, earth, etc.
1306. JOINTS
The thickness of joints shall not exceed

10mm. All joints on exposed faces shall be tooled to
give concave finish.
1307. LAYING
All brickwork shall be laid in an English

bond, even and true to line, in accordance with the
drawing or as directed by the Engineer, plumb and
level and all joints accurately kept. Half and cut
bricks shall not be used except when necessary to
complete the bond. Closer in such cases shall be cut
to the required size and used near the ends of the
walls. The bricks used at the face and also at all
angles forming the junction of any two walls shall be
selected whole bricks of uniform size, with true and
rectangular faces.
All bricks shall be laid with frogs up on a full

bed of mortar except in the case of tile bricks. Each
brick shall be properly bedded and set in position by
Page 904 of 1427

slightly pressing while laying, so that the mortar gets
into all their surface pores to ensure proper adhesion.
All head and side joints shall be completely filled by
applying sufficient mortar to brick already placed
and on brick to be placed. All joints shall be properly
flushed and packed with mortar so that no hollow
spaces arc left No bats or cut bricks shall be used
except to obtain dimensions of the different courses
for specified bonds or wherever a desired shape so
requires.
The brick work shall be built in uniform

layers, and for this purpose wooden straight edge
with graduations indicating thickness of each course
including joint shall be used. Corners and other
advanced work shall be raked back. Brickwork shall
be done true to plumb or in specified batter. All
courses shall be laid truly horizontal and vertical
joints shall be truly vertical. Vertical joints in
alternate courses shall come directly one over the
other. During construction, no part of work shall rise
more .than one metre above the general construction
level, to avoid unequal settlement and improper
jointing. Where this is not possible in the opinion of
the Engineer, the works shall be raked back
according to the bond (and not toothed) at an angle
not steeper than 45 degrees with prior approval of
the Engineer. Toothing may also be permitted where
future extension is contemplated.
Before laying bricks in foundation, the
Page 905 of 1427

foundation slab shall be thoroughly hacked, swept
clean and wetted. A layer of mortar not less than 12
mm thick shall be spread on the surface of the
foundation slab and the first course of bricks shall be
laid.
1308. JOINTING OLD AND NEW WORK
Where fresh masonry is to join with masonry

that is partially/entirely set, the exposed jointing
surface of the set masonry shall be cleaned,
roughened and wetted, so as to effect the best
possible bond with the new work. All loose bricks
and mortar or other material shall be removed.
In the case of vertical or inclined joints, it

shall be further ensured that proper bond between the
old and new masonry is obtained by interlocking the
bricks. Any portion of the brickwork that has been
.completed shall remain undisturbed until thoroughly
set.
In case of sharp corners specially in skew

bridges, a flat cutback of 100 mm shall be provided
so as to have proper and bonded laying of bricks.
1309. CURING
Green work shall be protected from rain by

suitable covering and shall be kept constantly moist
on all faces for a minimum period of seven days.
Brick work carried out during the day shall be
Page 906 of 1427

suitably marked indicating the date on which the
work is done so as to keep a watch on the curing
period. The top of the masonry work shall be left
flooded with water at the close of the day. Watering
may be done carefully so as not to disturb or wash
out the green mortar.
During hot weather, all finished or partly
completed work shall be covered or wetted in such a
manner as will prevent rapid drying of the
brickwork.
During the period of curing of brick work, it
shall be suitably protected from all damages. At the
close of day’s work or for other period of cessation,
watering and curing shall have to be maintained.
Should the mortar perish i.e. become dry, white or
powdery through neglect of curing, work shall be
pulled down and rebuilt as directed by the Engineer.
If any stains appear during watering, the same shall
be removed from the face.
1310. SCAFFOLDING
The scaffolding shall be sound, strong and

safe to withstand all loads likely to come upon it.
The holes which provide resting space for horizontal
members shall not be left in masonry under one
metre in width or immediately near the skew backs
of arches. The holes left in the masonry work for
supporting the scaffolding shall be filled and made
good. Scaffolding shall be got approved by the
Engineer. However, the Contractor shall be
responsible for its safety.
Page 907 of 1427

1311. EQUIPMENT
All tools and equipment used for mixing,

transporting and laying of mortar and bricks shall be
clean and free from set mortar, din or other injurious
foreign substances.
1312. FINISHING OF SURFACES
1312.1. General
All brickwork shall be finished in a

workmanlike manner with the thickness of joints,
manner of striking or tooling as described in these
above specifications.
The surfaces can be finished by “jointing” or

“pointing” or by “plastering” as given in the
drawings.
For a surface which is to be subsequently

plastered or pointed, the joints shall be squarely
raked out to a depth of IS mm, while the mortar is
still green. The raked joints shall be well brushed to
remove dust and loose particles and the surface shall
be thoroughly washed with water, cleaned and
wetted.
The mortar for finishing shall be prepared as

per Clause 1304.
1312.2. Jointing
Page 908 of 1427

In jointing, the face of the mortar shall be
worked out while still green to give a finished
surface flush with the face of the brick work. The
faces of brick work shall be cleaned to remove any
splashes of mortar during the course of raising the
brick work.
1312.3. Pointing
Pointing shall be carried out using mortar not

leaner than 1:3 by volume of cement and sand or as
shown on the drawing. The mortar shall be filled and
pressed into the raked joints before giving the
required finish. The pointing shall be ruled type for
which it shall, while still green, be ruled along the
centre with half round tools of such width as may be
specified by the Engineer. The super flush mortar
shall then be taken off from the edges of the lines
and the surface of the masonry shall be cleaned of all
mortar. The work shall conform to IS:2212.
1312.4. Plastering
Plastering shall be done where shown on the

drawing. Superficial plastering may be done, if
necessary, only in structures situated in fast flowing
rivers or in severely aggressive environment.
Plastering shall be started from top and

worked down. All putlog holes shall be properly
filled in advance of the plastering while the
Page 909 of 1427

scaffolding is being taken down. Wooden screeds 75
mm wide and of the thickness of the plaster shall be
fixed vertically 2.5 to 4 metres apart, to act as gauges
and guides in applying the plaster. The mortar shall
be laid on the wall between the screeds using the
plaster’s float and pressing the mortar so that the
raked joints are properly filled. The plaster shall then
be finished off with a wooden straight edge reaching
across the screeds. The straight edge shall be worked
on the screeds with a small upward and sideways
motion 50 mm to 75 mm at a time. Finally, the
surface shall be finished off with a plasterer’s
wooden float. Metal floats shall not be used.
When recommencing the plastering beyond

the work suspended earlier, the edges of the old
plaster shall be scrapped, cleaned and wetted before
plaster is applied to the adjacent areas.
No portion of the surface shall be left

unfinished for patching up at a later period.
The plaster shall be finished true to plumb

surface and to the proper degree of smoothness as
The average thickness of plaster shall not be

less than the specified thickness. The minimum
thickness over any portion of the surface shall not be
less than the specified thickness by more than 3 mm
Any cracks which appear in the surface and
Page 910 of 1427

all portions which sound hollow when tapped, or are
found to be soft or otherwise defective, shall be cut
in rectangular shape and re-done as directed by the
Engineer.
1312.5. Curing of Finishes
Curing shall be commenced as soon as the

mortar used for finishing has hardened sufficiently
not to -be damaged during curing. It shall be kept
wet for a period of at least 7 days. During this
period, it shall be suitably protected from all
damages.
1312.6. Scaffolding for Finishes
Stage scaffolding shall be provided for the

work. This shall be independent of the structure.
1313. ARCHITECTURAL COPING

FOR WING/RETURN/ PARAPET WALL
This work shall consist of providing an

Architectural coping for wing/return/parapet walls.
The material used shall be cement mortar 1:3

or as shown on the drawings prepared in accordance
with Clause 1304.
The cement mortar shall be laid evenly to an
average thickness of 15 mm to the full width of the
top of the wall and in continuation a band of 15 mm
thickness and 150 mm depth shall be made out of the
Page 911 of 1427

mortar along the top outer face of the walls.
1314. ACCEPTANCE OF WORK
All work shall be true 10 the lines and levels

as indicated on the drawing or as directed by the
Engineer, subject to tolerances as indicated in these
specifications.
Mortar cubes shall be tested in accordance

with IS:2250 for compressive strength, consistency
of mortar and its water retentivity. The frequency of
testing shall be one sample for every 2 cubic metres
of mortar, subject to a minimum 3 samples for a
day’s work.
In case of plaster finish, the minimum surface
thickness shall not be less than the specified
thickness by more than 3mm.

PAYMENT
All brick work shall be measured in cubic

metres. Any extra work done by the Contractor over
the specified dimensions shall be ignored.
In arches, the length of arch shall be

measured as the mean length between the extrados
and intrados.
The work of plastering and pointing shall be

measured in square metres of the surface treated.
Page 912 of 1427

Architectural coping shall be measured in
linear metres.
1316. RATE
The contract unit rate for brick work shall

include the cost of all labour, materials, tools and
plant, scaffolding and other expenses incidental to
the satisfactory completion of the work, sampling,
testing and supervision as described in these
specifications and as shown on the drawings.
The contract unit rate for plastering shall

plant, scaffolding and all incidental expenses,
sampling and testing and supervision as described in
The contract unit rate for pointing shall

include erecting and removal of scaffolding, all
labour, materials, and equipment incidental to
complete the pointing, raking out joints, cleaning,
wetting, filling with mortar, trowelling, pointing and
watering, sampling and testing and supervision as
described in these specifications.
The contract unit rate for architectural coping

shall include cost of all labour, materials, tools and
plant, sampling and testing and supervision as
Page 913 of 1427

Page 914 of 1427
Stone Masonry
1400
Stone Masonry
Page 915 of 1427

1401. DESCRIPTION
This work shall consist of the construction of

structures with stones jointed together by cement
mortar in accordance with the details shown on the
drawings and these specifications or as approved by
the Engineer.
1402. MATERIALS
All materials used in stone masonry shall

conform to Section 1000 except cement mortar for
stone masonry which shall conform to Clause 1304.
1403. PERSONNEL
Only trained personnel shall be employed for

construction and supervision.
1404. TYPE OF MASONRY
The type of masonry used for structures shall

be random masonry (coursed or uncoursed) or
coursed rubble masonry (First sort). However, for
bridge work generally, course rubble stone masonry
shall be used. The actual type of masonry used for
different parts of structures shall be specified on the
drawings.
For facing work, ashlar masonry shall be

used where indicated on the drawings.
Page 916 of 1427

1405. CONSTRUCTION OPERATIONS
1405.1. General Requirements
The dressing of stone shall be as specified for

individual type masonry work and it shall also
conform to the general requirements of IS: 1597 and
requirement for dressing of stone covered in IS:
1129. Other specific requirements are covered
separately with respect to particular types of rubble
stone work.
1405.2. Laying
1405.2.1. The masonry work shall be laid to

lines, levels, curves and shapes as Shown in the plan.
The height in each course shall be kept same and
every stone shall be fine tooled on all beds joints and
face full and true. The exposed faces shall be gauged
out, grooved, regulated and sunk or plain moulded as
the case may be. The faces of each stone between the
draft be left rough as the stone comes from quarry
except where sacrificial layer is to be provided or
plastering is resorted to due to aggressive
environment.
1405.2.2. Stones shall be sufficiently wetted

before laying to prevent absorption of water from
mortar.
Stratified stones must be laid on their natural

beds. AH bed joints shall be normal to the pressure
Page 917 of 1427

upon them.
Stones in the hearting shall be laid on their

broadest face that gives a better opportunity to fill
the spaces between stones.
The courses of the masonry shall ordinarily

be pre-determined. They shall generally be of the
same height. When there is to be variation in the
height of courses, the larger courses arc to be placed
at lower levels, heights of courses decreasing
gradually towards the top of the wall. The-practice
of placing loose mortar on the course and pouring
water on it to fill the gaps in stones is not acceptable.
Mortar may be fluid mixed thoroughly and then
poured in the joints. No dry or hollow space shall be
left anywhere in the masonry and each stone shall
have all the embedded faces completely covered
with mortar.
In tapered walls, the beds of the stones and

the planes of course should be at right angles to the
batter. In case of bridge piers with batter on both
sides, the course shall be horizontal.
The bed which is to receive the stone shall be

cleaned, wetted and covered with a layer of fresh
mortar. All stones shall be laid full in mortar both in
bed and vertical joints and settled carefully in place
with a wooden mallet immediately on placement and
solidly embedded in mortar before it has set Clean
chips and spails shall be wedged into the mortar
Page 918 of 1427

joints and bed wherever necessary to avoid thick
beds or joints of mortar. When the foundation
masonry is laid directly on rock, the face stones of
the first course shall be dressed to fit into rock
snugly when pressed down in the mortar bedding
over the rock. No dry or hollow space shall be left
anywhere in the masonry and each stone shall have
all the embedded faces completely covered with
mortar. For masonry works over rock, a levelling
course of 100 mm thickness and in concrete M 15
shall be laid over rock and then stone masonry work
shall be laid without foundation concrete block.
Face works and hearting shall be brought up

evenly but the top of each course shall not be
levelled up by the use of flat chips.
For sharp corners specially in skew bridges,

through stones shall be used in order to avoid
spalling of corners.
In case any stone already set in mortar is

disturbed or the joints broken, it shall be taken out
without disturbing the adjoining stones and joints.
Dry mortar and stones thoroughly cleaned from the
joints and stones and the stones reset in fresh mortar.
Attempt must never be made to slide one stone on
top of another, freshly laid.
Shaping and dressing shall be done before

the stone is laid in the work. No dressing and
hammering, which will loosen the masonry, will be
Page 919 of 1427

allowed after it is once placed. All necessary chases
for joggles, dowels and clamps should be formed
before hand.
Sufficient transverse bonds shall be provided

by the use of bond stone extending from the front to
the back of the wall and in case of thick wall from
outside to the interior and vice versa. In the latter
case, bond stones shall overlap each other in their
arrangement.
In case headers are not available, precast

headers of M 15 concrete shall be used. Cast-in-situ
headers are not permitted.
Stones shall break joint on the face for at

least half the height of the course and the bond shall
be carefully maintained throughout.
In band work at all angle junctions of walls,

the stones at each alternate course shall be carried
into each of the respective walls so as to unite the
work thoroughly.
The practice of building up thin faces tied

with occasional through stones and Tilling up the
middle with small stuff or even dry packing is not
acceptable.
All quoins and the angles of the opening shall

be made from selected stones, carefully squared and
bedded and arranged to bond alternately long and
Page 920 of 1427

short in both directions.
All vertical joints shall be truly vertical.

Vertical joints shall be staggered \ as far as possible.
Distance between the nearer vertical joints of upper
layer and lower shall not be less than half the height
of the course.
Only rectangular shaped bond stones or

headers shall be used. Bond stones shall overlap
each other by 150 mm or more.
All connected masonry in a structure shall be

carried up nearly at one uniform level throughout but
when breaks are unavoidable the masonry shall be
raked in sufficiently long steps to facilitate jointing
of old and new work. The stepping of raking shall
not be more than 45 degrees with the horizontal.
1405.3. Random Masonry (Uncoursed and

Coursed)
1405.3.1. Dressing : Stone shall be hammer

dressed on the face, .the sides and beds to enable
it to come in proximity with the neighbouring stone’.
The bushing on the exposed face shall not be more
than 40 mm.
1405.3.2 Insertion of chips : Chips and

spalls of stone may be used wherever necessary to
avoid thick mortar beds or joints and it shall be
ensured that no hollow spaces are left anywhere in
Page 921 of 1427

the masonry. The chips shall not be used below
hearting stones to bring these upto the level of face
stones. Use of chips shall be restricted to filling of
interstices between the adjacent stones in hearting
and they shall not exceed 20 per cent of the quantity
of stone masonry.
1405.3.3. Hearting stones : The hearting

or interior filling of the wall face shall consist of
rubble stones not less than 150 mm in any direction,
carefully laid, hammered down with a wooden
mallet into position and solidly bedded in mortar.
The hearting should be laid nearly level with
facing and backing.
1405.3.4. Bond stones : Through bond

stones -shall be provided in masonry upto 600
mm thickness and in case of masonry above 600 mm
thickness, a set of two or more bond stones
overlapping each other at least by 150 mm shall be
provided in a line from face to back. -In case of
highly absorbent types of stones (porous limestone
and sandstones, etc.,) the bond stone shall extend
only about two-third into the wall, as through
stones in such cases may give rise to penetration of
dampness and therefore, for all thicknesses of such
masonry, a set of two or more bond stones
overlapping each other by at least 150 mm shall
be provided. One bond stone or a set of bond stones
shall be provided for every 0.50 sq. m. of the
masonry surface.
Page 922 of 1427

1405.3.5. Quoin stone : Quoin stone i.e.
stone specially selected and neatly dressed for
forming an external angle in masonry work, shall not
be less than 0.03 cubic metre in volume.
1405.3.6. Plum stone : The plum stones

are selected long stones embedded vertically in the
interior of the masonry to form a bond between
successive courses and shall be provided at about
900 mm intervals.
1405.3.7. Laying : The masonry shall be laid

with or without courses as specified. The quoins
shall be laid header and stretcher alternately. Every
stone shall be fitted to the adjacent stone so as to
form neat
and close joint. Face stone shall extend and
bond well in the back. These shall be arranged
to break joints, as much as possible, p- and to
avoid long vertical lines of joints.
1405.3.8. Joints : The face joints shall not
be more than 20 mm thick, but shall be sufficiently
thick to prevent stone-to-stone contact d shall be
completely filled with mortar.
1405.4. Square Rubble - Coursed Rubble

(First Sort)
1405.4.1. Dressing : Face stones shall be

hammer dressed on all beds and joints so as to
give them rectangular shape. These shall be square
on all joints and beds. The bed joints shall be chisel
Page 923 of 1427

drafted for at least 80 mm back from the face and
for at least 40 mm for the side joints. No portion of
the dressed surface shall show a depth Of gap more
than 6 mm from the straight edge placed on it.
The remaining unexposed portion of the stone shall
not project beyond the surface of bed and side joints.
The requirements regarding bushing shall be the
same as for random rubble masonry.
1405.4.2. Hearting stones : The hearting

or interior filling of the wall face shall consist of flat
bedded stone carefully laid, on prepared beds in
mortar. The use of chips shall be restricted to the
filling of interstices between the adjacent stones in
hearting and these shall not exceed 1-0 per cent of
the quantity of masonry. While using chips it shall
be ensured that no hollow spaces are left anywhere
in the masonry.
1405.4.3. Bond stones : The requirements

regarding through or bond stone shall be the same as
for random rubble masonry, but these, shall be
provided at 1.5 metre to 1.8 metre apart clear in
every course.
1405.4.4. Quoin stone : The quoins shall

be of the same height of the course in which these
occur and shall be formed of header stones not less
than 450mm in length. They shall be laid lengthwise
alternately along each face, square in their beds
which shall be fairly dressed to a depth of at least
100 mm.
Page 924 of 1427

1405.4.5. Face stone : Face stones shall
tail into the work for not less than their heights
and at least one-third of the stones shall tail into the
work for a length not less than twice their height.
These shall be laid as headers and stretchers
alternately.
1405.4.6. Laying : The stones shall be laid

on horizontal courses and all vertical joints should be
truly vertical. The quoin stones should be laid
header and stretcher alternately and shall be laid
square on their beds, which shall be rough chisel
dressed to a depth of at least 100 mm.
1405.4.7. Joints : The face joints shall not be

more than 10 mm thick, but shall be sufficiently
thick to prevent stone-to-stone contact and shall be
completely filled with mortar.
1405.5. Ashlar Masonry (Plain Ashlar)
1405.5.1. Dressing : Every stone shall be

cut to the required size and shape, chisel dressed on
all beds and joints so as to be free from all bushing.
Dressed surface shall not show a depth of gap of
more than 3 mm from straight edge placed on it.
The exposed faces and joints, 6 mm from the face
shall be fine tooled so that a straight edge can be
laid along the face of the stone in contact with
every point. All visible angles and edges shall be
true and square and free from chippings. The corner
Page 925 of 1427

stones (quoins) shall be dressed square and comer
shall be straight and vertical.
1405.5.2. Bond stones : Through bond

stones shall be provided in masonry upto 600
mm thickness and in case of masonry above 600 mm
thickness, a set of two or mere bond stones
overlapping each other at least by 150 mm shall be
provided in a line from face to back. In case of
highly absorbent types of stones (porous limestone
and sandstones, etc.,) the bond stone shall extend
only about two-third into the wall, as through
stones in such cases may give rise to penetration of
dampness and, therefore, for all thicknesses of such
masonry a set of two or more bond stones
overlapping each, other by at least 150 mm shall be
provided. One bond stone or a set of bond stones
shall be 1.5 metres to 1.8 metres apart clear in every
course.
1405.5.3. Laying : The face stone shall be

laid header and stretcher alternately, the header
being arranged to come as nearly as possible in the
middle of stretchers above and below. Stones shall
be laid in regular courses not less than 300 mm in
height and all courses of the same height unless
otherwise specified. No stone shall be less in
width than its height or less in length than twice its
height, unless otherwise specified.
1405.5.4. Joints : All joints shall be full of

mortar. These shall not be less than 3 mm thick.
Page 926 of 1427

Face joints shall be uniform throughout, and a
uniform recess of 20 mm depth from face shall be
left with the help of a stone plate during the
progress of work.
1405.6. Pointing
Pointing shall be carried out using mortar not

leaner than 1:3 by volume of cement and sand or .as
shown on the drawing. The mortar shall be filled and
pressed into the raked out joints before giving the
required finish. The pointing shall conform to Clause
1312.3 of the specification. The work shall conform
to . IS:2212. The thickness of joints shall not be less
than 3 mm for Ashlar masonry. However, the
maximum thickness of joints in different works shall
be as follows:
Random Rubble : 20 mm
Coursed Ruble : 15 mm
Ashlar Masonry : 5 mm
1405.7. Curing
Curing shall conform to Clauses 1309 and

1312.5
1405.8. Scaffolding
For scaffolding Clause 1310 shall apply.
1405.9. Weep Holes
Page 927 of 1427

Weep holes shall conform to Clause 2706.
1405.10. Jointing with Existing Structures
For Jointing with existing structures, the

specifications given under Clause 1308 shall apply.
1406. ARCHITECTURAL COPING

FOR WING/RETURN/ PARAPET WALLS
Architectural coping for wing/return/parapet

walls shall conform to clause 1313.
1407. TESTS AND STANDARD OF

ACCEPTANCE
All work shall be done to the lines and levels

as indicated on he drawing or as directed by the
Engineer subject to tolerances as specified in these
specifications.
Mortar cubes shall be taken in accordance

with IS:2250 for compressive strength, consistency
of mortar and its water retentivity. The frequency of
testing shall be one sample for every two cubic
metres of mortar subject to a minimum 3 samples for
a day’s work.

PAYMENT
Stone masonry shall be measured in cubic
Page 928 of 1427

metres.
In arches, the length of arch shall be

measured as the mean length between the extrados
and intrados.
The work of pointing shall be measured in

square metres. Architectural coping shall be
measured in linear metres.
1409. RATE
The contract unit rate for stone masonry shall

plant, scaffolding, sampling and testing, supervision
and other expenses incidental to the satisfactory
completion of the work as described herein above.
The contract unit rate for pointing shall
include erecting and removal of scaffolding, all
labour, materials and equipment incidental to
complete pointing, raking out joints, cleaning,
wetting, filling with mortar, trowelling, pointing and
watering, sampling and testing and supervision as
The contract rate for architectural coping
shall include the cost of all labour, materials, tools
and plant, sampling and testing and supervision as
Page 929 of 1427

Formwork
1500
Formwork
Page 930 of 1427

1501. DESCRIPTION
Formwork shall include all temporary or

permanent forms required for forming the concrete
of the shape, dimensions and surface finish as shown
on the drawing or as directed by the Engineer,
together with all props, staging, centering,
scaffolding and temporary construction required for
their support. The design, erection and removal of
formwork shall conform to IRC:87 “Guidelines for
Design and Erection of Falsework for Road Bridges”
and these specifications.
1502. MATERIALS
All materials shall comply with the

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

timber. The metal used for forms shall be of such
thickness that the forms remain true to shape. All
bolts should be countersunk. The use of approved
internal steel ties or steel or plastic spacers shall be
permitted. Structural steel tubes used as support for
forms shall have a minimum wall thickness of 4 mm.
Page 931 of 1427

Other materials conforming to the requirements of
IRC:87 may also be used if approved by the
Engineer.
1503. DESIGN OF FORMWORK
1503.1. The Contractor shall furnish the

design and drawing of complete formwork (i.e. the
forms as well as their supports) for approval of the
Engineer before any erection is taken up. If
proprietary system of formwork is used, the
Contractor shall furnish detailed information as per
Appendix 150011 to the Engineer for approval.
Notwithstanding any approval or review of
drawing and design by the Engineer, the Contractor
shall be entirely responsible for the adequacy and
safety for formwork.
1503.2. The design of the formwork shall

conform 10 provisions of IRC:87. It shall ensure that
the forms can be conveniently removed without
disturbing the concrete. The design shall
facilitate proper and safe access to all parts of
formwork for inspection.
1503.3. In the case of prestressed concrete

superstructure, careful consideration shall be given
to redistribution of loads on props due to
prestressing.
1504. WORKMANSHIP
1504.1. The formwork shall be robust and
Page 932 of 1427

strong and the joints shall be leak-proof.
Balli shall not be used as staging. Staging

must have cross bracings and diagonal bracings in
both directions. Staging shall be provided with an
appropriately designed base plate resting on firm
strata.
1504.2. The number of joints in the

formwork shall be kept to a minimum by using
large size panels. The design shall provide for proper
“soldiers” to facilitate alignment. All joints shall be
leak proof and must be properly sealed. Use of
PVC JOINT sealing tapes, foam rubber or PVC
T-section is essential to prevent leakage of grout.
1504.3. As far as practicable, clamps shall

be used to hold the forms together. Where use of
nails is unavoidable minimum number of nails
shall be used and these shall be left projecting so
that they can be withdrawn easily. Use of double
headed nails shall be preferred.
1504.4. Use of ties shall be restricted, as far

as practicable. Wherever ties are used they shall be
used with HDPE sheathing so that the ties can easily
be removed. No parts prone to corrosion shall be left
projecting or near the surface. The sheathing shall be
grouted with cement mortar of the same strength as
that of the structure.
1504.5. Unless otherwise specified, or
Page 933 of 1427

directed, chamfers or fillets of sizes 25 mm x 25 mm
shall be provided at all angles of the formwork to
avoid sharp corners. The chamfers, bevelled
edges and mouldings shall be made in the
formwork itself. Opening for fixtures and other
fittings shall be provided in the shuttering as
1504.6. Shuttering for walls, sloping

members and thin sections of considerable height
shall be provided with temporary openings to
permit inspection and cleaning out before placing of
concrete.
1504.7. The formwork shall be constructed

with precamber to the soffit to allow for deflection
of the formwork. Pre-camber 10 allow for
deflection of formwork shall be in addition to that
indicated for the permanent structure in the
drawings.
1504.8. Where centering trusses or

launching trusses are adopted
for casting of superstructure, the joints of the
centering trusses, whether welded, riveted or bolted
should be thoroughly checked periodically. Also,
various members of the centering trusses should be
periodically examine J for proper alignment and
unintended deformation before proceeding with the
concreting. They shall also be periodically checked
for any deterioration in quality due to steel
corrosion.
Page 934 of 1427

1504.9. The formwork shall be so made as
to produce a finished concrete true to shape, line
and levels and dimensions as shown on the
drawings, subject to the tolerances specified in
respective sections of these specifications, or as
1504.10. Where metal forms are used,

all bolts and rivets shall be countersunk and well
ground to provide a smooth, plane surface. Where
timber is used it shall be well seasoned, free from
loose knots, projecting nails, splits or other defects
that may mar the surface of concrete.
1504.11. Forms shall be made sufficiently

rigid by the use of ties and bracings to prevent any
displacement or sagging between supports. They
shall be strong enough to withstand all pressure,
ramming and vibration during and after placing the
concrete. Screw jacks or hard wood wedges where
required shall be provided to make up any settlement
in the formwork either before or during the placing
of concrete.
1504.12. The formwork shall take due

account of the calculated amount of positive or
negative camber so as to ensure the correct final
shape of the structures, having regard to the
deformation of false work, scaffolding or propping
and the instantaneous or deferred deformation due to
various causes affecting prestressed structures.
Page 935 of 1427

1504.13. Suitable camber shall be provided
to horizontal members of structure, specially in
long spans to counteract the effects of deflection.
The formwork shall be so fixed as to provide for
such camber.
1504.14. The formwork shall be coated with

an approved release agent that will effectively
prevent sticking and will not stain the concrete
surface. Lubricating (machine oils) shall be
prohibited for use as coating.
1505. FORMED SURFACE AND

FINISH
The formwork shall be lined with material

approved by the Engineer so as to provide a smooth
finish of uniform texture and appearance. This
material shall leave no stain on the concrete and so
fixed to its backing as not to impart any blemishes. It
shall be of the same type and obtained from only one
source throughout for the construction of any one
structure. The contractor shall make good any
imperfections in the resulting finish as required by
the Engineer. Internal ties and -embedded metal pans
shall be carefully detailed and their use shall be
subject to the approval of the Engineer.
1506. PRECAUTIONS
(i) Special measures in the design of
Page 936 of 1427

formwork shall be taken to ensure that it
does not hinder. the shrinkage of
concrete. The soffit of the formwork shall
be so designed as to ensure that the
formwork does not restrain the shortening
and/or hogging of beams during
prestressing. The forms may be removed
at the earliest opportunity subject to the
minimum time for removal of forms with
props retained in position.
(ii) Where necessary, formwork shall be so

arranged that the soffit form, properly
supported on props only can be retained
in position for such period as may be
required by maturing conditions
(iii) Any cut-outs or openings provided in any

structural member to facilitate erection of
formwork shall be closed with the same
grade of concrete as the adjoining
structure immediately after removal of
formwork ensuring watertight joints.
(iv) Provision shall be made for safe access

on, to and about the formwork at the
levels as required.
(v) Close watch shall be maintained to check

for settlement of formwork during
concreting. Any settlement of formwork
during concreting shall be promptly
Page 937 of 1427

rectified.
(vi) Water used for curing should not be

allowed to stagnate near the base plates
supporting the staging and should be
properly drained.
1507. PREPARATION OF FORMWORK

BEFORE CONCRETING
The inside surfaces of forms shall, except in

the case of permanent form work or where otherwise
agreed to by the Engineer be coated with a release
agent supplied by approved manufacturer or of an
approved material to prevent adhesion of concrete to
the formwork. Release agents shall be applied
strictly in accordance with the manufacturer’s
instructions and shall not be allowed to come into
contact with any reinforcement or prestressing
tendons and anchorages. Different release agents
shall not be used in formwork for exposed concrete.
Before re-use of forms, the following actions

shall be taken :
(i.) The contact surfaces of the forms shall be

cleaned carefully and dried before
applying a release agent.
(ii.) It should be ensured that the release agent
is appropriate to the surface to be coated.
The same type and make of release agent
shall be used throughout on similar
Page 938 of 1427

formwork materials and different types
should not be mixed.
(iii.) The form surfaces shall be evenly and
thinly coated with release agent The
vertical surface shall be treated before
horizontal surface and any excess wiped
out.
(iv.) The release agent shall not come in
contact with reinforcement or the
hardened concrete.
All forms shall be thoroughly cleaned

immediately before concreting.
The Contractor shall give the Engineer due

notice before placing any concrete in the forms to
permit him to inspect and approve the formwork, but
such inspection shall not relieve the contractor of his
.responsibility for safety of formwork, men,
machinery, materials and finish or tolerances of
concrete.
1508. REMOVAL OF FORMWORK
The scheme for removal of formwork (i.e.

de-shuttering and de-centering) shall be planned in
advance and furnished to the Engineer for scrutiny
and approval. No formwork or any part thereof shall
be removed without prior approval of the Engineer.
The formwork shall be so removed as not to

cause any damage to concrete. Centering shall be
Page 939 of 1427

gradually and uniformly lowered in such a manner as
to permit the concrete to take stresses due to its own
weight uniformly and gradually to avoid any shock .
or vibration.
Where not specifically approved, the time of

removal of formwork (when ordinary Portland
Cement is used without any admixtures at an
ambient temperatures exceeding 10 degrees Celsius)
shall be as under :
Walls, piers, 12 to 48 hours as may be

abutments, columns decided by the Engineer
and vertical faces of
structural members
Soffits of Slabs (with 3 days
props left under)
Props (left under 14 days
slabs)
Soffit of Girders 7 days
(with props left
under)
Props (left under 21 days
girders)
Where there are re-entrant/angles in the

concrete sections, the formwork should be removed
at these sections as soon as possible after the
concrete has set, in order to avoid cracking due to
shrinkage of concrete.
1509. RE-USE OF FORMWORK
Page 940 of 1427

When formwork is dismantled, its individual
components shall be examined for damage and
damaged pieces shall be removed for rectification.
Such examination shall always be carried out before
being used again. Before re-use all components shall
be cleaned of deposits of soil, concrete or other
unwanted materials. Threaded parts shall be oiled
after cleaning.
All bent steel props shall be straightened

before re-use. The maximum deviation from
straightness is 1/600 of the length. The maximum
permissible axial loads in used props shall be
suitably reduced depending upon their condition.
The condition of the timber components, plywood
and steel shuttering plates shall be examined closely
for distortion and defects before re-use.
1510. SPECIALISED FORMWORK
Specialised formwork may be required in the

case of slipform work, underwater concreting,
segmental construction etc. Such specialised form-
work shall be designed and detailed by competent
agencies and a set of complete working drawings
and installation instructions shall be supplied to the
Engineer. The site personnel shall be trained in the
erection and dismantling as well as operation of such
specialised formwork. In case proprietary equipment
is used, the supplier shall supply drawings, details,
installation instructions, etc., in the form of manuals
Page 941 of 1427

along with the formwork. Where specialised
formwork is used, close co-ordination with the
design of permanent structure is necessary.
For slipform the rate of slipping the

formwork shall be designed for each individual case
taking into account various parameters including the
grade of concrete, concrete strength, concrete
temperature, ambient temperature, concrete
admixtures, etc. In the case of segmental construc-
tion, the concrete mix shall be normally designed for
developing high early strength so that the formwork
is released as early as possible.
In order to verify the time and sequence of

striking/removal of specialised formwork, routine
field tests for the consistency of concrete and
strength development are mandatory and shall be
carried out before adoption.
For specialised formwork, the form lining

material may be either plywood or steel sheet of
appropriate thickness. Plywood is preferred where
superior quality of surface is desired, whereas steel
sheeting is normally used where large number of
repetitions are involved.

ACCEPTANCE

Page 942 of 1427


1512. MEASUREMENTS FOR PAYMENT
Unless stated otherwise the rate for concrete

in Plain Concrete or Reinforced Concrete or
Prestressed Concrete shall be deemed to include all
formwork required in accordance with this section
and shall not be measured separately.
Where it is specifically stipulated in the

Contract that the formwork shall be paid for
separately, measurement of formwork shall be taken
in square metres of the surface area of concrete
which is in contact with formwork.
1513. RATE
The unit rate of the Plain Concrete or

Reinforced Concrete or Prestressed Concrete as
defined in respective sections shall be deemed to
cover the costs of all formwork, including cost of all
materials, labour, tools and plant required for design,
construction and removal of formwork and
supervision as described in this section including
properly supporting the members until the concrete
is cured, set and hardened as required.
Page 943 of 1427

Where the contract unit rate for formwork is
specifically provided as a separate item, it shall
include the cost of all materials, labour, tools and
plant required for design, construction and removal
of formwork and supervision as described in this
Section including properly supporting the members
until the concrete is cured, set and hardened as
required.
Page 944 of 1427

Steel Reinforcement (Untensioned)
1600
Steel Reinforcement
(Untensioned)
Page 945 of 1427

1601. DESCRIPTION

placing coated or uncoated mild steel or high
strength deformed reinforcement bars (untensioned)
of the shape and dimensions shown on the drawings
and conforming to these Specifications or as
1602. GENERAL
Steel for reinforcement shall meet with the

requirements of Section 1000.
Reinforcements may be either mild
steel/medium tensile steel or high strength deformed
bars. They may be uncoated or coated with epoxy or
with-approved protective coatings.
1603. PROTECTION OF REINFORCEMENT
Uncoated reinforcing steel shall be protected

from rusting or chloride contamination.
Reinforcements shall be free from rust, mortar, loose
mill scale, grease, oil or paints. This may be ensured
either by using reinforcement fresh from the factory
or thoroughly cleaning all reinforcement to remove
rust using any suitable method such as sand blasting,
mechanical wire brushing, etc.. as directed by the
Engineer. Reinforcements shall be stored on blocks,
racks or platforms and above the ground in a clean
and dry condition and shall be suitably marked to
facilitate inspection and identification.
Page 946 of 1427

Portions of uncoated reinforcing steel and
dowels projecting from concrete, shall be protected
within one week after initial placing of concrete with
a brush coat of neat cement mixed with water to a
consistency of thick paint This coating shall be
removed by lightly tapping with a hammer or other
tool not more than one week before placing of the
adjacent pour of concrete. Coated reinforcing steel
shall be protected against damage to the coating. If
the coating on the bars is damaged during
transportation or handling and cannot be repaired,
the same shall be rejected.
1604. BENDING OF REINFORCEMENT
Bar bending schedule shall be furnished by

the Contractor and got approved by the Engineer
before start of work.
Reinforcing steel shall conform to the

dimensions and shapes given in the approved Bar
Bending Schedules.
Bars shall be bent cold to the specified shape

and dimensions or as directed by the Engineer using
a proper bar bender, operated by hand or power to
obtain the correct radii of bends and shape.
Bars shall not be bent or straightened in a

manner that will damage the parent material or the
coating.
Page 947 of 1427

Bars bent during transport or handling shall
be straightened before being used on work and shall
not be heated to facilitate straightening.
1605. PLACING OF REINFORCEMENT
a) The reinforcement cage should generally

be fabricated in the yard at ground level
and then shifted and placed in position.
The reinforcement shall be placed
strictly in accordance with the drawings
and• shall be assembled in position only
when the structure is otherwise ready for
placing of concrete. Prolonged time gap
between assembling of reinforcements
and casting of concrete, which may
remit in rust formation on the surface,
shall not be permitted.
b) Reinforcement ban shall be placed
accurately in position as shown on the
drawings. The bars, crossing one another
shall be tied together at every’
intersection with binding wire
(annealed), conforming to 15:280 to
make the skeleton of the reinforcement
rigid such that the reinforcement does
not get displaced during placing of
concrete, or any other operation. The
diameter of binding wire shall not be
less than 1 mm.
c) Bars shall be keg’, in position usually by
Page 948 of 1427

the following methods: .
i) In case of beam and stab

construction, industrially produced
polymer cover blocks of thickness
equal to the specified cover shall
be placed between the ban and
formwork subject to satisfactory
evidence that the polymer
composition is not harmful to
concrete and reinforcement. Cover
blocks made of concrete may be
permitted by the Engineer,
provided they have the same
strength and specification as those
of the member.
ii) In case of dowels for columns and
walls, the vertical reinforcement
shall be kept in position by means
of timber templates with slots cut
in them accurately, or with cover
blocks tied to’ the reinforcement.
Timber templates shall be
removed after the concreting has*
progressed upto a level just below
their location.
iii) Layers of reinforcements shall be
separated by spacer ban at
approximately one metre intervals.
The minimum diameter of spacer
ban shall be 12 nun or equal to
maximum size of main
Page 949 of 1427

reinforcement or maximum size of
coarse aggregate, whichever is
greater. Horizontal reinforcement
shall not be allowed to sag.
between supports.
iv) Necessary stays, blocks, metal
chain, spacers, metal hangers,
supporting wires etc, or other
subsidiary reinforcement shall be
provided 10 fix the reinforcements
firmly in its correct position.
v) Use of pebbles broken stone, metal
pipe, brick, mortar or wooden
blocks etc., as devices for
positioning reinforcement shall not
be permitted.
d) Ban coated with epoxy or any other

approved protective coating shall be
placed on supports that do not damage
die coaling. Supports shall be installed
in manner such that planet of weakness
an not created in hardened concrete. The
coated reinforcing Reel shall be held in
place by OK of plastic or plastic coaled
binding wires especially manufactured
for the purpose. Reference shall be made
to Section 1000 for other requirements.
e) Placing and fixing of reinforcement shall
be impeded and approved by the
Engineer before concrete is deposited.
Page 950 of 1427

1606. BAR SPLICES
1606.1. Lapping
All reinforcement shall be furnished in full

lengths as indicated on the drawing. No splicing of
bars, except where shown on the drawing, will be
permitted without approval of the Engineer. The
lengths of the splice shall be as indicated on drawing
or as approved by the Engineer. Where practicable,
overlapping bars shall not touch each other, and shall
be kept apart by 25 mm or I ¼ times the maximum
size of course aggregate, whichever is greater. If this
is not feasible, overlapping bars shall be bound with
annealed steel binding wire, not less than 1 mm
diameter and twisted tight in such a manner as to
maintain minimum clear cover to the reinforcement
from the concrete surface. Lapped splices shall be
staggered or located at points, along the span where
stresses are low.
1606.2. Welding
1606.2.1. Splicing by welding of

reinforcement will be permitted only if detailed on
the drawing or approved by the Engineer. Weld shall
develop an ultimate strength equal to or greater than
that of the bars connected.
1606.2.2. While welding may be permitted

for mild steel reinforcing bars conforming to IS:432,
welding of deformed bars conforming to 1S:1786
Page 951 of 1427

shall in general be prohibited. Welding may be
permitted in case of bars of other than S 240 grade
including special welding grade of S 41S grade bars
conforming to IS: 1786, for which necessary
chemical analysis has been secured and the carbon
equivalent (CE) calculated from the chemical
composition using the formula :
Mn Cr  Mg  V Ni  Cu
CE  C   
6 5 15
is 0.4 or less
1606.2.3. The method of welding shall

conform to IS:2751 and 15:9417 and to any
supplemental specifications to the satisfaction of the
Engineer.
Welding may be carried out by metal arc

welding process. Oxy-acetelene welding shall not be
permissible. Any other process may be used subject
to the approval of the Engineer and necessary
additional requirements to ensure satisfactory joint
performance. Precautions on over heating, choice of
electrode, selection of correct current in arc welding
etc., should be strictly observed.
All bars shall be butt welded except for

smaller diameter bars (diameter of less than 20 mm)
which may be lap welded. Single-V or Double-V
bun joints may generally be used. For vertical bars
Page 952 of 1427

single bevel or double bevel joints may be used.
Welded joints shall be located well away

from bends and not less than twice the bar diameter
away from a bend.
Generally, shop welding in controlled

conditions is to be preferred, where feasible. Site
welding where necessary shall, however, be
permitted when the facilities, equipment, process,
consumables, operators, welding procedure are
adequate to produce and maintain uniform quality at
par with that attainable in shop welding to the
Joint welding procedures which are to be

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

the bars securely in position during welding. It must
be ensured that no voids are left in welding. When
welding is done in 2 or 3 stages, previous surface
shall be cleaned properly. Bars shall be cleaned of all
loose scale, rust, grease, paint and other foreign
Page 953 of 1427

matter before carrying out welding. Oily competent
and experienced welders shall be employed on the
work with the approval of the Engineer. No welding
shall be done on coated bars.
M.S. electrodes used for welding shall

conform to IS:814.
1606.2.4. Welded joints shall preferably be

located at points where steel will not be subject to
more than 75 per cent of the maximum permissible
stresses and welds so staggered that at any one
section, not more than 20 per cent of the bars are
welded.
1606.2.5. Welded pieces of reinforcement

shall be ‘tested. Specimens shall be taken from the
site and the number and frequency of tests shall be as
1606.3. Mechanical Coupling of Bars
Bars may be joined with approved patented

mechanical devices as indicated on the drawing or as
approved by the Engineer e.g. by special grade steel
sleeves swagged on to bars in end to end contact or
by screwed couplers. In case such devices are
permitted by the Engineer, they shall develop at least
125 per cent of the characteristic strength of the
reinforcement bar.
1607. TESTING AND ACCEPTANCE
Page 954 of 1427

The material shall be tested in accordance
with relevant IS specifications and necessary test
certificates shall be furnished. Additional tests, if
required, will be got carried out. by the Contractor at
his own cost.
The fabrication, furnishing and placing of
reinforcement shall be in accordance with these
specifications and shall be checked and accepted, by
the Engineer.
Reinforcement shall be measured in length

including hooks, if any, separately for different
diameters as actually used in work, excluding
overlaps. From the length so measured, the weight of
reinforcement shall be calculated in tonnes on the
basis of 15:1732. Wastage, overlaps, couplings:
welded joints, spacer bars, chairs, stays, hangers and
annealed steel wire or other methods for binding and
placing shall not be measured and cost of these items
shall be deemed to be included in. the rates for
reinforcement
1609. RATE
The contract unit rate for coated/uncoated

reinforcement shall cover the cost of material,
fabricating, transporting* storing, bending, placing,
binding and fixing in position as shown on the
drawings as per these specifications and as directed
Page 955 of 1427

by the Engineer, including all labour, equipment,
supplies, incidentals, sampling, testing and
supervision.
The unit rate for coated reinforcement shall

be deemed to also include cost of all material,
labour, tools and plant, royalty, transportation and
expertise required to carry out the work. The rate
shall also cover sampling, testing and supervision
required for the work.
Page 956 of 1427

Structural Concrete
1700
Structural Concrete
Page 957 of 1427

1701. DESCRIPTION
The work shall consist of furnishing and

placing structural concrete and incidental
construction in accordance with these specifications
and in conformity with the lines, grades and
dimensions, as shown -on the drawings or as
1702. MATERIALS
All materials shall conform to Section 1000

of these Specifications. 1703. GRADES OF
CONCRETE
1703.1. The grades of concrete shall be

designated by the characteristic strength as given in
Table 1700-1, where the characteristic strength is
defined as the strength of concrete below which not
more than 5 per cent of the test results are expected
to fall.
TABLE 1700-1.
Specified characteristic
Grade Designation Compressive strength of
150 mm cubes at 28 days,
In MPa
M 15 15
M 20 20
M 25 25
M 30 30
M 35 35
Page 958 of 1427

M 40 40
M 45 45
M 50 50
M 55 55
1703.2. The lowest grades of concrete in

bridges and corresponding minimum cement
contents and water-cement ratios shall be maintained
as indicated in Tables 1700-2 and 1700-3.
TABLE 1700-2 FOR BRIDGES WITH

PRESTRESSED
CONCRETE OR
THOSE WITH
INDIVIDUAL SPAN
LENGTHS MORE
THAN 30 M OR THOSE
THAT ARE BUILT
WITH INNOVATIVE
DESIGN/CON-
STRUCTION
(A) MINIMUM CEMENT CONTENT AND

MAXIMUM WATER CEMENT RATIO
Structural Member Mm. cement content for all Max.

exposure conditions (kg/cu.m.) Exposu
Normal
a) PCC members 360 0.45
b) RCC members 400 0.45
c) PSC members 400 0.40
Page 959 of 1427

(B) MINIMUM STRENGTH OF CONCRETE
Member
Conditions of Expo
Normal
a) PCC members M 25
b) RCC members M 35
c) PSC members M 35
TABLE 1700-3 FOR BRIDGES OTHER

THAN THOSE
MENTIONED IN
TABLE 1700-2 AND
FOR CULVERTS AND
OTHER INCIDENTAL
CONSTRUCTION
(A) MINIMUM CEMENT CONTENT AND
MAXIMUM WATER CEMENT RATIO
Structural Member Min. cement content M

(Kg/ cu.m.)
Exposure Conditions Expos
Normal Severe Normal
a) PCC members 250 310 0.50
b) RCC members 310 400 0.45
(B) MINIMUM STRENGTH OF CONCRETE
Member
Conditions of Expo
Normal
Page 960 of 1427

a) PCC members M 15
b) RCC members M 20
Notes Applicable to Tables 1700-2 and 1700-

3
(i) The minimum cement content ii bated

on 20 mm aggregate (nominal max.
size). For 40 mm and larger size
aggregates, it may be reduced suitably
but the reduction shall not be more than
10 per cent
(ii) For underwater concreting, the cement
content shall be increased by 10 per
cent
(iii) Severe conditions of exposure shall
mean alternate wetting and drying due
to sea spray, alternate wetting and
drying combined with freezing and
buried in soil having corrosive effect
(iv) Moderate conditions of exposure shall
mean other that those mentioned in (iii)
above.
The cement content shall be as low as

possible but not less than the quantities specified
above. In no case shall it exceed 540 kg/cu.m. of
concrete.
1703.3. Concrete used in any component or

structure shall be specified by designation along with
prescribed method of design of mix . i.e. “Design
Page 961 of 1427

Mix” .or “Nominal Mix”. For all items of concrete,
only “Design Mix” shall be used, except where
“Nominal Mix” concrete is permitted as per drawing
or by the Engineer.”Nominal Mix” may be permitted
only for minor bridges and culverts or other
incidental construction where strength requirements
are upto M 20 only. “Nominal Mix” may also be
permitted for non-structural concrete or for screed
below open foundations.
1703.4. If the Contractor so elects, the

Engineer may permit the use of higher grade
concrete than that specified on the drawing, in which
event the higher grade concrete shall meet the
specifications applicable thereto without additional
compensation.
1704. PROPORTIONING OF CONCRETE
Prior to the start of construction, the

Contractor shall design the mix in case of “Design
Mix Concrete” or propose nominal mix in case of
“Nominal Mix Concrete”, and submit to the
Engineer for approval, the proportions of materials,
including admixtures to be used. Water-reducing
admixtures (including plasticisers or super-
plasticisers) may be used at the Contractor’s option,
subject to the approval of the Engineer. Other types
of admixtures shall be prohibited, unless specifically
permitted by the Engineer.
1704.1. Requirements of Consistency
Page 962 of 1427

The mix shall have the consistency which
will allow proper placement and consolidation in the
required position. Every attempt shall be made to
obtain uniform consistency.
The optimum consistency for various types

of structures shall be as indicated in Table 1700-4. or
as directed by the Engineer. The slump of concrete
shall be checked as per IS:516.
TABLE 1700-4.
SLUMP
TYPE
(mm)
1 (a) Structures with exposed 25

inclined surface
requiring low slump 25
concrete to allow proper
compaction
(b) plain cement concrete
2. RCC structures with widely 40 - 50
spaced reinforcements; e.g.
solid columns, piers,
abutments, footings, well
iteming
3. RCC structures with fair 50 - 75
degree of congestion of
reinforcement; e.g. pier and
abutment caps, box culverts
well curb, well cap, walls
with thickness greater than
Page 963 of 1427

300 mm
4. RCC and PSC structures with 75 -
highly congested 125
reinforcements e.g. deck slab
girder:, box girders, walls
with thickness less than 300
mm
5. Underwater concreting 100 -
through tremie 200 e.g. 200
bottom plug, cast-in-situ
piling.
1704.2. Requirements for Designed Mixes
1704.2.1. Target mean strength
The target mean strength of specimen shall

exceed the specified characteristic compressive
strength by at least the “current margin”.
(i.) The current margin for a concrete mix

shall be determined by the Contractor
and shall be taken as 1.64 limes the
standard deviation of sample test results
taken from at least 40 separate batches
of concrete of nominally similar
proportions produced at site by the same
plant under similar supervision, over a
period exceeding 5 days, but not
exceeding 6 months.
(ii.) Where there is insufficient data to satisfy
Page 964 of 1427

the above, the current margin for the
initial design mix shall be taken as given
in Table 1700-5 :
TABLE 1700-5.
Concrete Grade Current Margin Tar

(MPa)
M 15 10
M 20 10
M 25 11
M 30 12
M 35 12
M 40 12
M 45 13
M 50 13
M 55 14
The initial current margin given in the Table

1700-5 shall be used till sufficient data is available
to determine the current margin as per sub-clause (i)
above
1704.2.2. Trial mixes
The Contractor shall give notice to enable the

Engineer to be present at the making of trial mixes
and preliminary testing of the cubes. The Contractor
shall prepare trial mixes, using samples of approved
materials typical of those he proposes to use in the
works, for all grades to the Engineer’s satisfaction
prior to commencement of concreting. The initial
Page 965 of 1427

trial mixes shall generally be carried out in an
established laboratory approved by the Engineer. In
exceptional cases, the Engineer may permit the
initial trial mixes to be prepared at the site laboratory
of the Contractor, if a full fledged concrete
laboratory has been established well before the start
of construction, to his entire satisfaction. In all
cases* complete testing of materials forming the
constituents of proposed Design Mix shall have been
carried out prior to making trial mixes.
Sampling and testing procedures shall be in

accordance with these specifications.
When the site laboratory is utilised for

preparing initial mix design, the concreting plant and
means of transport employed to make the trial mixes
shall be similar to that proposed to be used in the
works.
Test cubes shall be taken from trial mixes as

follows. For each mix, set of six cubes shall be made
from each of three consecutive batches. Three cubes
from each set of six shall be tested at an age of 28
days and three at an earlier age approved by the
Engineer. The cubes shall be made, cured, stored,
transported and tested in accordance with these
specifications. The average strength of the nine
cubes at 28 days shall exceed the specified
characteristic strength by the current margin minus
3.5 MPa.
Page 966 of 1427

1704.23. Control of strength of design
mixes
a) Adjustment to Mix Proportions
Adjustments to mix proportions arrived

at in the trial mixes shall be made
subject to the Engineer’s approval, in
order to minimise the variability of
strength and to maintain the target
mean strength. Such adjustments shall
not be taken to imply any change in the
current margin.
b) Change of Current Margin
When required by the Engineer, the

Contractor shall recalculate the current
margin in accordance with Clause
1704.2.1. The recalculated value shall
be adopted as directed by the Engineer,
and it shall become the current margin
for concrete produced subsequently.
c) Additional Trial Mixes
During production, the Contractor shall

carry cut trial mixes and tests, if
required by the Engineer, before
substantial changes are made in the
material or in the proportions of the
materials to be used, except when
adjustments to the mix proportions are
carried out in accordance with sub-
Page 967 of 1427

clause (a) above.
1704.3. Requirements of Nominal Mix

Concrete
Requirements for nominal mix concrete

unless otherwise specified, shall be as detailed in
Table 1700-6.
TABLE 1700-6. PROPORTIONS FOR

NOMINAL MIX CONCRETE
Concrete Total Quantity of Proportion of

Grade dry aggregate by fine to Coarse
mass per 50 kg of aggregate (by
cement to be taken mass)
as the sum of
individual masses
of fine and coarse
aggregates (kg)
M15 350 Generally 1:2,

subject to upper
limit 1:1.5 and
lower limit of
M20 250 1:2.5
-----do-------
1704.4. Additional Requirements
Page 968 of 1427

Concrete shall meet with any other
requirements as specified on the drawing or as
directed by the Engineer. Additional requirements
shall also consist of the following overall limits of
deleterious substances in concrete :
a) The total chloride content of all

constituents of concrete as a percentage
of mass of cement in mix shall be
limited to values given below:
 Prestressed Concrete
: 0.1 per cent
 Reinforced concrete exposed to
chlorides in service : 0.2 per
cent (e.g. structures located near
tea coast)
 Other reinforced concrete
construction :
0.3 per cent
b) The total sulphuric anhydride (SO2)
content of all the constituents of
concrete as a percentage of mass
cement in the mix shall be limited to
4 per cent.
1740.5. Suitability of Proposed Mix Proportions
The Contractor shall submit the following

information for the Engineer’s approval
a) Nature and source of each material

b) Quantities of each material per cubic metre of
Page 969 of 1427

fully compacted concrete
c) Either of the following :
i) appropriate existing data as evidence of
satisfactory previous performance for the
target mean strength, current margin,
consistency and water/cement ratio and any
other additional requirements) as specified
ii) full details of tests on trial mixes.
d) Statement giving the proposed mix proportions

for nominal mix concrete.
Any change in the source of material or in

the mix proportions shall be subject to the
Engineer’s prior approval.
1705. ADMIXTURES
Use of admixtures such as super plasticisers

for concrete may be made with the approval of the
Engineer.
As the selection of an appropriate concrete

admixture is an integral pan of the mix design, the
manufacturers shall recommend the use of any one
of his products only after obtaining complete
knowledge of all the actual constituents of concrete
as well as methodologies of manufacture,
transportation and compaction of concrete proposed
to be used in the project
1706. SIZE OF COARSE AGGREGATE
Page 970 of 1427

The size (maximum nominal) of coarse
aggregates for concrete to used in various
components shall be given as Table 1700-7.
TABLE 1700-7.
Components Maximum Nominal

Size of Coarse
Aggregate (nun)
(i.) RCC well curb 20
(ii.) RCC/PCC well 40

steining
40
(iii.) Well cap or Pile Cap
Solid type piers and
abutments 20
(iv.) RCC work in girders

slibs, wearing coat,
kerb, approach slab, 20
hollow piers and
abutments,
pier/abutment caps, As specified by
piles Engineer
(v.) PSC work
(vi.) Any other item
Page 971 of 1427

Maximum nominal size of aggregates shall
also be restricted to the smaller of the following
values :
a) 10 mm less than the minimum lateral
clear distance between main
reinforcements
b) 10 mm less than the minimum clear
cover to the reinforcements
The proportions of the various individual size

of aggregates shall be so adjusted that the grading
produces densest mix and the grading curve
corresponds to the maximum nominal size adopted
for the concrete mix.
1707. EQUIPMENT
Unless specified otherwise, equipment for

production, transportation and compaction of
concrete shall be as under :
a) For Production of Concrete :

i) For overall bridge length of less
than 200 metres - batch type
concrete mixer diesel or electric
operated, with a minimum size of
200 litres, automatic water
measuring system and integral
weigher (hydraulic/pneumatic
type)
ii) For overall bridge length of 200
Page 972 of 1427

mares or more - concrete batching
and mixing plant fully automatic
with minimum capacity of 15
cu.m. per hour.
All measuring devices of the equipment shall

be maintained in a clean and serviceable condition.
Its accuracy shall be checked over the range in use,
when set up at each site and thereafter periodically
The accuracy of the measuring devices shall

fall within the following limits:
Measurement of ± 3 per cent of the quantity of

Cement cement in each batch

Water water in each batch

Aggregate aggregate in each batch

Admixture admixture in each batch
b) For Concrete Transportation : depending

i) Concrete upon
dumpers actual
ii) Powered hoists requiremen
iii) Chutes t
iv) Buckets handled minimum
Page 973 of 1427

by cranes 2 tonnes
v) Transit truck capacity
mixer minimum
vi) Concrete pump O.S tonne
vii) Concrete capacity
distributor booms
viii) Belt-conveyor
ix) Cranes with skips
x) Tremies
c) For Compaction of Concrete : size 25 mm to
i) Internal vibrators 70 mm
ii) Form vibrators minimum 500
iii) Screed vibrators watts full width
of carriageway
(upto two
lanes)
1708. MIXING CONCRETE
Concrete shall be mixed either in a concrete

mixer or in a batching and mixing plant, as per these
specifications. Hand mixing shall not be permitted.
The mixer or the plant shall be at an approved
location considering the properties of the mixes and
the transportation arrangements available with the
Contractor. The mixer or the plant shall be approved
by the Engineer.
Mixing shall be continued till materials are

uniformly distributed and a uniform colour of the
Page 974 of 1427

entire mass is obtained, and each individual particle
of the coarse aggregate shows complete coating of
mortar containing its proportionate amount of
cement. In no case shall mixing be done for less than
2 minutes.
Mixers which have been out of use for more

than 30 minutes shall be thoroughly cleaned before
putting in a new batch. Unless otherwise agreed to
by the Engineer, the first batch of concrete from the
mixer shall contain only two thirds of the normal
quantity of coarse aggregate. Mixing plant shall be
thoroughly cleaned before changing from one type
of cement to another.
1709. TRANSPORTING, PLACING AND

COMPACTION OF CONCRETE
The method of transporting and placing

concrete shall be approved by the Engineer.
Concrete shall be transported and placed as near is
practicable to its final position, so that no
contamination, segregation or loss of its constituent
materials takes place. Concrete shall not be freely
(bopped into place from a height exceeding 1.5
metres.
When concrete is conveyed by chute, the

plant shall be of such size and design as to ensure
practically continuous flow. Slope of the chute shall
be so adjusted that the concrete flows without the
use of excessive quantity of water and without any
Page 975 of 1427

segregation of its ingredients. The delivery end of
the chute shall be as close as possible to the point of
deposit. The chute shall be thoroughly flushed with
water before and after each working period and the
water used for this purpose shall be discharged
outside the formwork.
All formwork and reinforcement contained in

it shall be cleaned and made free from standing
water, dust, snow or ice immediately before placing
of concrete.
No concrete shall be placed in any part of the

structure until the approval of the Engineer has been
obtained.
If concreting is not started within 24 hours of

the approval being given, it shall have to be obtained
again from the Engineer. Concreting then shall
proceed continuously over the area between the
construction joints. Fresh concrete shall not be
placed against concrete which has been In position
for more than 30 minutes unless a proper
construction joint is formed.
Except where otherwise agreed to by the

Engineer, concrete shall be deposited in horizontal
layers to a compacted depth of not more than 450
mm when internal vibrators are used and not
exceeding 300 mm in all other cases.
Concrete when deposited shall have a
Page 976 of 1427

temperature of not less than 5 degrees Celsius, and
not more than 40 degrees Celsius. It shall be
compacted in its final position within 30 minutes of
its discharge from the mixer, unless carried in
properly designed agitators, operating continuously,
when this time shall be within 1 hour of the addition
of cement to the mix and within 30 minutes of its
discharge from the agitator. It may be necessary to
add retarding admixtures to concrete if trials show
that the periods indicated above are unacceptable. In
all such matters, the Engineer’s decision shall be
final.
Concrete shall be thoroughly compacted by

vibration or other means during placing and worked
around the reinforcement, tendons or duct formers,
embedded fixtures and into corners of the formwork
to produce a dense homogeneous void-free mass
having the required surface finish. When vibrators
are used, vibration shall be done continuously during
the placing of each batch of concrete until the
expulsion of air has practically ceased and in a
manner that does not promote segregation. Over
vibration shall be avoided to minimise the risk of
forming a weak surface layer. When external
vibrators are used, the design of formwork and
disposition of vibrator shall be such as to ensure
efficient compaction and to avoid surface blemishes.
Vibrations shall not be applied through
reinforcement and where vibrators of immersion
type are used, contact with reinforcement and all
inserts like ducts etc, shall be avoided. The internal
Page 977 of 1427

vibrators shall be inserted in an orderly manner and
the distance between insertions should be about one
and a half times the radius of the area visibly
affected by vibration. Additional vibrators in
serviceable condition shall be kept at site so that they
can be used in the event of breakdowns.
Mechanical vibrators used shall comply with

IS:2502, IS:2506, 1S:2514 and IS:4656.
1710. CONSTRUCTION JOINTS
Construction joints shall be avoided as far as

possible and in no case the locations of such joints
shall be changed or increased from those shown on
the drawings, except with express approval of the
Engineer. The joints shall be provided in a direction
perpendicular to the member axis.
Location, preparation of surface and

concreting of construction joints shall conform to the
additional specifications given in Appendix 170011.
1711. CONCRETING UNDER WATER
When it is necessary to deposit concrete

under water, the methods, equipment, materials and
proportions of mix to be used shall be got approved
from the Engineer before any work is started.
Concrete shall contain 10 per cent more cement than
that required for the same, mix placed in the dry.
Page 978 of 1427

Concrete shall not be placed in water having
a temperature below 5 degrees Celsius. The
temperature of the concrete, when deposited, shall
not be less than 16 degrees Celsius, nor more than 40
degrees Celsius.
Coffer dams or forms shall be sufficiently

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

out by tremic method only, using tremie of
appropriate diameter. The number and spacing of the
tremies should be worked out to ensure proper
concreting. The tremie concreting when started
should continue without interruption for the full
height of the member being concreted. The concrete
production and placement equipment should be
sufficient to enable the underwater concrete to be
completed uninterrupted within die stipulated time.
Necessary stand-by equipment should be available
for emergency situation.
Page 979 of 1427

The top section of the tremie shall have a
hopper large enough to hold one full batch of the
mix or the entire contents of the transporting bucket
as the case may be. The tremie pipe shall not be less
than 200 mm in diameter and shall be large enough
to allow a free flow of concrete and strong enough to
withstand the external pressure of the water in which
it is suspended, even if a partial vacuum develops
inside the pipe. Preferably, flanged steel pipe of
adequate strength for the job shall be used. A
separate lifting device shall be provided for each
tremie pipe with its hopper at the upper end. Unless
the lower end of the pipe is equipped with an
approved automatic check valve, the upper end of
the pipe shall be plugged with a wadding of gunny
sacking or other approved material before delivering
the concrete to the tremie pipe through the hopper,-
so that when the concrete is forced down from the
hopper to the pipe, it will force the plug (and along
with it any water in the pipe) down the pipe and out
of the bottom end, thus establishing a continuous
stream of concrete. It will be necessary to raise
slowly the tremie in order to allow a uniform flow of
concrete, but it snail not be emptied so that water is
not allowed to enter above the concrete in the pipe.
At all times after placing of concrete is started and
until all the required quantity has been placed, the
lower end of the tremie pipe shall be kept below the
surface of the plastic concrete. This will cause the
concrete to build up from below instead of flowing
out over the surface and thus avoid formation of
layers of laitance. If the charge in the tremie is lost
Page 980 of 1427

while depositing, the tremie shall be raised above the
concrete surface and unless sealed by a check valve,
it shall be replugged at the top end, as at the
beginning, before refilling for depositing further
concrete.
1712. ADVERSE WEATHER CONDITIONS
1712.1. Cold Weather Concreting
Where concrete is to be deposited at or near

freezing temperature, precautions shall be taken to
ensure that at the time of placing, it has a
temperature of not less than 5 degrees Celsius and
that the temperature of the concrete shall be
maintained above 4 degrees Celsius until it has
thoroughly hardened. When necessary, concrete
ingredients shall be heated before mixing but cement
shall not be heated artificially other than by the heat
transmitted to it from other ingredients of the
concrete. Stock-piled aggregate may be heated by
the use of dry heat or steam. Aggregates shall not be
heated directly by gas or on sheet metal over fire. In
genera), the temperature of aggregates or water shall
not exceed 65 degrees Celsius. Salt or other
chemicals shall not be used for the prevention of
freezing. No frozen material or materials containing
ice shall be used. All concrete damaged by frost shall
be removed. It is recommended that concrete
exposed to freezing weather shall have entrained air
and the water consent of the mix shall not exceed 30
litres per 50 kg of cement.
Page 981 of 1427

1712.2. Hot Weather Conditions
When depositing concrete in very hot

weather, precautions shall be taken so that the
temperature of wet concrete does not exceed 40
degrees Celsius while placing. This shall be achieved
by stacking aggregate under the shade and keeping
them moist, using cold water, reducing the time
between mixing and placing to the minimum,
cooling form work by sprinkling water, starting
curing before concrete dries out and restricting
concreting as far as possible to early mornings and
late evenings. When ice is used to cool mixing
water, it will be considered a part of the water in
design mix. Under no circumstances shall the mixing
operation be considered complete until all ice in the
mixing drum has melted.
The Contractor will be required to state his

methodology for the Engineer’s approval when
temperatures of concrete are likely to exceed 40
degrees Celsius during the work.
1713. PROTECTION AND CURING
Concreting operations shall not commence

until adequate arrangements for concrete curing have
been made by the Contractor.
Curing and protection of concrete shall start

immediately after compaction of the concrete to
Page 982 of 1427

protect it from :
a) Premature drying out particularly by

solar radiation and wind
b) High internal thermal gradients
c) Leaching out by rain and flowing
water
d) Rapid cooling during the first few
days after placing
e) Low temperature or frost
f) Vibration and impact which may
disrupt the concrete and interfere with
its bond to the reinforcement
Where members are of considerable size and

length, with high cement content, accelerated curing
methods may be applied, as approved by the
Engineer.
1713.1. Water Curing
Water for curing shall be as specified in

Section 1000.
Sea water shall not be used for curing. Sea

water shall not come into contact with concrete
members unless it has attained adequate strength.
Exposed surfaces of concrete shall be kept

continuously in a damp or wet condition by ponding
or by covering with a layer of sacks, canvas, Hessian
or similar materials and shall be kept constantly wet
Page 983 of 1427

for a period of not less than 14 days from the date of
placing of concrete.
1713.2. Steam Curing
Where steam curing is adopted, it shall be

ensured that it. is done in a suitable enclosure to
contain the live steam in order to minimise moisture
and beat losses. The initial application of the steam
shall be after about four hours of placement of
concrete to allow the initial set of the concrete to
take place.
Where retarders are used, the waiting period

before application of the steam shall be increased to
about six hours.
The steam shall be at 100 per cent relative

humidity to prevent loss of moisture and to provide
excess moisture for proper hydration of the cement.
The application of steam shall not be directly on the
concrete and the ambient air temperature shall
increase at a rate not exceeding 5 degrees Celsius per
hour until a maximum temperature of 60 degrees
Celsius to 70 degrees Celsius is reached. The
maximum temperature shall be maintained until the
concrete has reached the desired strength.
When steam curing is discontinued, the

ambient air temperature shall not drop at a rate
exceeding 5 degrees Celsius per hour until a
temperature of about 10 degrees Celsius above the
Page 984 of 1427

temperature of the air to which the concrete will be
exposed, has been reached.
The concrete shall not be exposed to

temperatures below freezing for at least six days
after curing.
1713.3. Curing Compounds
Curing compounds shall only be permitted in

special circumstances and will require specific
approval of the Engineer. Curing compounds shall
not be used on any surface which requires further
finishing to be applied. All construction joints shall
be moist, cured and no curing compound will be
permitted in locations where concrete surfaces are
required to be bonded together.
Curing compounds shall be continuously

agitated during use. All concrete cured by this
method shall receive two applications of the curing
compound. The first coat shall be applied
immediately after acceptance of concrete finish. If
the surface is dry, the concrete shall be saturated
with water and curing compound applied as soon as
the surface film of water disappears. The second
application shall be made after the first application
has set. Placement in more than two coats may be
required to prevent streaking.
1714. FINISHING
Page 985 of 1427

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

completed work shall be left carefully tooled and
free from any mortar and concrete. Expansion joint
filler shall be left exposed for its full length with
clean and true edges.
Immediately on removal of forms, the

concrete work shall be examined by the Engineer
before any defects are made good.
a) The work that has sagged or contains
Page 986 of 1427

honeycombing to an extent
detrimental to structural safety or
architectural appearance shall be
rejected
b) Surface defect of a minor nature may
be accepted. On acceptance of such
work by the Engineer, the same shall
be rectified as directed by the
Engineer.
1715. TOLERANCES
Tolerances for dimensions/shape of various

components shall be as indicated in these
specifications or shown on the drawings or as

ACCEPTANCE
1716.1. Concrete shall conform to the

surface finish and tolerance a? prescribed in these
specifications for respective components.
1716.2. Random sampling and lot by lot of

acceptance inspection shall be made for the 28 days
cube strength of concrete.
1716.2.1. Concrete under acceptance shall be

notionally divided into lots for the purpose of
sampling, before commencement of work. The
delimitation of lots shall be determined by the
Page 987 of 1427

following :
(i.) No individual lot shall be more than 30

cu.m. in volume
(ii.) At least one cube forming an item of the
sample representing the lot shall be taken
from concrete of the same grade and mix
proportions cast on any day.
(iii.) Different grades of mixes of concrete
shall be divided into separate lots
(iv.) Concrete of a lot shall be used in the
same identifiable component of the
bridge
1716.2.2. Sampling and testing
1. Concrete for making 3 test cubes shall

be taken from a batch of concrete at
point of delivery into construction,
according to procedure laid down in IS:
1199.
2. A random sampling procedure to ensure
that each of the concrete batches
forming the lot under acceptance
inspection has equal chance of being
chosen for taking cubes shall be
adopted.
3. ISO mm cubes shall be made, cured and
tested at the age of 28 days for
compressive strength in accordance with
IS;516. The 28-day lest strength result
for each cube shall form an item of the
Page 988 of 1427

sample.
1716.2.3. Test specimen and sample

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

average of the strength of 3 cubes. The individual
variation should not be more than ± 15 per cent of
the average.
1716.2.4. Frequency : The minimum

frequency of sampling of concrete of each grade
shall be in accordance with Table 1700-8
TABLE 1700-8
Quantity of Concrete In work, m3 No. of samples

1-5 1
6 - 15 2
16 - 30 3
31-50 4
51 and above 4 plus one additional s
additional 50 m1 or pa
At least one sample shall be taken from each

shift of work.
1716.2.5. Acceptance criteria
Page 989 of 1427

Compressive Strength
When both the following conditions are met,

the concrete complies with the specified compressive
strength :
a) The mean strength determined from
any group of four consecutive
samples should exceed the specified
characteristic compressive strength.
b) Strength of any sample is not less
than the specified characteristic
compressive strength minus 3 MPa.
The quantity of concrete represented by the

test results include the batches from which the first
and last samples were taken, together with ail
intervening batches.
Chloride and Sulphate Content
The total chloride and sulphuric anhydride

(SO3) content of all the constituents of concrete as a
percentage of mass of cement in the mix shall not
exceed the values given in this section of the
specifications.
1716.3. Density of Fresh Concrete
Where minimum density of fresh concrete is

specified, the mean of any four consecutive samples
shall not be less than the specified value and any
Page 990 of 1427

individual sample result shall not be less than 97.5
per cent of the specified value.
1716.4. Density of Hardened Concrete
Where minimum density of hardened

concrete is specified, the mean of any four
consecutive samples shall not be less than the
specified value and any individual sample result
shall not be less than 97.5 per cent of the specified
value.
1716.5. Permeability Test
The concrete should pass the following test if

it is properly compacted and is not considered
permeable.
a) Prepare a cylindrical test specimen 150

mm din and 160 mm high
b) After 28 days of curing, the test specimen
is fitted in a machine such that the
specimen can be placed in water under
pressure upto 7 bars. A typical machine is
shown in Appendix 1700lll.
c) At first a pressure of one bar is applied
for 48 hours, followed by 3 bars for 24
hours and 7 bars for next 24 hours.
d) After the passage of the above period, the
specimen is taken out and split in the
middle by compression applied on two
round bars on opposite sides above and
Page 991 of 1427

below.
e) The water penetration in the broken core
is to be measured with a scale and the
depth of penetration assessed in mm
(max. permissible limit 25 mm).
1716.6. If the concrete is not able to meet

any of the standards of acceptance as prescribed, the
effect of such deficiency on the structure shall be
investigated by the Contractor as directed by the
Engineer. The Engineer may accept the concrete as
sub-standard work. Any additional work required by
the Engineer for such acceptance shall be carried cu;
by the Contractor at his cost. In case the concrete is
not found to be acceptable after investigation, the
Contractor shall remove the rejected concrete
forthwith.
Structural concrete shall be measured in

cubic metres. In reinforced or prestressed concrete,
the volume occupied by reinforcement or
prestressing cables and sheathing shah not be
deducted. The slab shall be measured as running
continuously through and the beam as the portion
below the slab.
1718. RATE
The contract unit rate for structural concrete

shall cover costs of all materials, labour, tools, plant
Page 992 of 1427

and equipment required for mixing, transporting and
placing in position, vibrating and compacting,
finishing and curing as per this Section or as directed
by the Engineer, including all incidental expenses,
sampling and testing, quality assurance and super-
vision. Unless mentioned separately as an item in the
Contract, the contract unit rate for concrete shall also
include the cost of providing, fixing and removing
formwork required for concrete work as per Section
1500.
Where concrete is found to be acceptable as

sub-standard work, the Contractor shall pay a
discount over the contract unit rate, as decided by the
Engineer. For deficiency in compressive strength of
concrete when accepted by the Engineer, the
reduction in rate may be applied as under :
Design Strength - Observed Strength

Per cent reduction  x10
Design Strength
Page 993 of 1427

Prestressing
1800
Prestressing
Page 994 of 1427

1801. DESCRIPTION
Structural concrete containing prestressed

steel reinforcement to introduce pre compression is
termed as prestressed concrete.
The work shall be carried out in accordance

with the drawing and specifications or as approved
by the Engineer.
Concrete and untensioned steel for the

construction of prestressed members shall conform
to the requirements of sections 1700 1600 for
Structural Concrete and Steel Reinforcement
respectively so far as the requirements of these
Sections apply and are not specifically modified
by requirements set forth herein.
1802. MATERIALS
1802.1. All materials shall conform to

Section 1000.
1802.2. Sheathing
1802.2.1. The sheathing ducts shall be of the

spiral corrugated type. Unless otherwise specified,
the material shall be Cold Rolled Cold Annealed
(CRCA) Mild Steel conforming to IS:513 intended
for mechanical treatment and surface refining but not
for quench hardening or tempering.
Page 995 of 1427

The material shall normally be bright
finished. However, where specified, as in case of use
in aggressive environment, galvanised or lead-coated
mild steel strips shall be used.
The thickness of sheathing shall be as shown

on the drawing, but shall not be less than 0.3 mm,
0.4 mm and 0.5 mm for sheathing ducts having
internal diameter of 50 mm, 75 mm and 90 mm
respectively. For bigger diameter of ducts, thickness
of sheathing shall be based on recommendations of
prestressing system supplier or as directed by the
Engineer.
The sheathing shall conform to the

requirement as per tests specified in Appendix
1800/I.
For major projects, the sheathing ducts

should preferably be manufactured at the project site
utilising appropriate machines. With such an
arrangement, long lengths of sheathing ducts may be
used with consequent reduction in the number of
joints and couplers. Where sheathing duct joints are
unavoidable, such joints shall be made slurry tight
by the’ use of corrugated threaded sleeve couplers
which may be tightly screwed onto the outer side of
the sheathing ducts.
The length of the coupler should not be less

than 150 mm but should be increased upto 200 mm
wherever practicable. The joints between the ends of
Page 996 of 1427

the coupler and the duct shall be sealed with
adhesive sealing tape to prevent penetration of
cement slurry daring concreting. The couplers of
adjacent ducts should be staggered wherever
practicable. As far as possible, couplers should not
be located in curved zones. The corrugated sleeve
couplers are being conveniently manufactured using
the sheath making machine with the next higher size
of die set.
1802.2.2. The internal area of the sheathing

duct shall be in accordance with the
recommendations of the system manufacturer and
shall be about three times the area of the tendons.
In case of 6T13, 12T13 and 19T13 sizes of tendons
comprising 12/13 mm dia strands, the inner diameter
of the sheathing shall not be less than 50 mm, 75 mm
and 90 mm respectively or those shown in the
drawing, which ever is greater.
Where prestressing tendons are required to be

threaded after concreting the diameter of sheathing
shall be about 5 nun larger than that required as
above.
1802.2.3. In severe environment, cables shall

be threaded after concreting. In such cases a
temporary tendon shall be inserted. in the
sheathing or the sheathing shall be stiffened by
other suitable method during concreting.
18023. Anchorages
Page 997 of 1427

18023.1. Anchorages shall be procured from
authorised manufacturers only. Anchorages shall
conform to BS:4447. Test certificates from a
laboratory fully equipped to carry out the tests shall
be furnished to the Engineer. Such test certificates
shall not be more than 12 months old at the time of
making the proposal for adoption of a particular
system for the project.
No damaged anchorages shall be used. Steel

parts shall be protected from corrosion at all times.
Threaded parts shall be protected by greased
wrappings and tapped holes shall be protected by
suitable plugs until used. The anchorage components
shall be kept free from mortar and loose rust and any
other deleterious coating.
18023.2. Swages of prestressing strand and

button-heads of prestressing wire, where provided
shall develop a strength of at least 95 per cent of the
specified breaking toad of the strand or wire as the
case may be. Where swaging/button-heading is
envisaged, the Contractor shall furnish details of his
methodology and obtain approval of the Engineer,
prior to his taking up the work.
1802.3.3. Untensioned Steel reinforcements,

around anchorages shall conform to the details of
prestressing system and as shown on the drawing.
1803. TESTING OF PRESTRESSING STEEL
Page 998 of 1427

AND ANCHORAGES
All materials specified for testing shall be

furnished free of cost and shall be delivered in time
for tests to be made well in advance of anticipated
time of use.
All wire, strand or bars to be shipped to the

site shall be assigned a lot number and tagged for
identification purposes. Anchorage assemblies to be
shipped shall be like-wise identified.
All samples submitted shall be representative

of the lot to be furnished and in the case of wire or
strand, shall be taken from the same master roll. The
Contractor shall furnish samples of at least 5.0 m
length selected from each lot for testing. . Also, two
anchorage assemblies, complete with distribution
plates of each size or types to be used, shall be
furnished along with short, lengths of strands as
required.
1804 WORKMANSHIP
1804.1. Cleaning
Tendons shall be free from loose rust, oil,

grease, tar, paint, mud or any other deleterious
substance.
Cleaning of the steel may be carried out by

immersion in suitable solvent solutions, wire
Page 999 of 1427

brushing or passing through a pressure box
containing carborundum powder. However, the
tendons shall not be brought to a polished condition.
1804.2. Straightening
High tensile steel wire and strand shall be

supplied in coils of sufficiently large diameter such
that tendons shall retain their physical properties and
shall be straight as it unwinds from the coil. Tendons
of any type that are damaged, kinked or bent shall
not be used. The packing of prestressing wire/strand
shall -be removed only just prior to making of cable
for placement Suitable stands shall be provided to
facilitate uncoiling of wires/strands without damage
to steel. Care shall be taken to avoid the possibility
of steel coming into contact with the ground.
1804.3. Positioning
1804.3.1. Post-Tensioning
Prestressing tendons shall be accurately

located and maintained in position, both vertically
and horizontally, as per drawings.
Tendons shall be so arranged that they have a

smooth profile without sudden bends or kinks.
The locationing of prestressed cables shall be

such as to facilitate easy placement and vibration of
concrete in between the tendons. High capacity
Page 1000 of 1427

tendon shall be used to reduce the number of cables
thereby eliminating the necessity of grouping. The
selected profiles of the tendons shall be such that
their anchorages are not located in the top deck
surface. Where two or more rows of cables have to
be used, the cables shall be vertically in line to
enable easy flow of concrete. The clear vertical and
horizontal distances between any two cables shall in
no case be less than 100mm anywhere along the
length of the superstructure. Where precast segments
are used, the clear distance shall be at least 150 mm.
Sheathing shall be placed in correct position

and profile by providing suitable, ladders and
spacers. Such ladders may be provided at intervals of
approximately 1.0 m. Sheathing shall be tied rigidly
with such ladders/spacer bars so that they do not get
disturbed during concreting.
The method of supporting and fixing shall be

such that profile of cables is not disturbed during
vibrations, by pressure of wet concrete, by workmen
or by construction traffic.
Sheathing in which the permanent tendon

will not be in place during concreting shall have a
temporary tendon inserted or shall be stiffened by
some other method to the approval of the Engineer.
The temporary tendon shall be pulled out before
threading the permanent tendon into place by a
special threading machine or other contrivance.
Page 1001 of 1427

Where possible tendons shall not be
placed until immediately prior to stressing.
Tendons shall be handled with care to avoid damage
or contamination, to either the tendon or the
sheathing. Any tendons damaged or contaminated
shall be cleaned or replaced.
1804.3.2. Pre-Tensioning. Prestressing steel

shall be accurately located and maintained in
position, both vertically and horizontally, as per
drawings.
1804.3.3. Each anchorage device shall be

set square to the line of action of the corresponding
prestressing tendon and shall be positioned securely
to prevent movement during concreting.
The anchorage devices shall be cleaned to the

satisfaction of the Engineer prior to the placing of
concrete. After concreting, any mortar or concrete
which adheres to bearing or wedging surfaces, shall
be removed immediately.
1804.4. Cutting
Cutting and trimming of wires or strands

shall be done by suitable mechanical or flame
cutters. When a flame cutter is used, care shall be
taken to ensure that the flame does not come in
contact with other stressed steel, The location of
flame cutting of wire or strand shall be kept beyond
75 mm of where the tendon will be gripped by. the
Page 1002 of 1427

anchorage or jacks.
In post-tensioning the ends of prestressing

steel projecting beyond the anchorages, shall be cut
after the grout has set.
1804.5. Protection of Prestressing Steel
Prestressing steel shall be continuously

protected against corrosion, until grouted. The
corrosion protector shall have no deleterious effect
on the steel or concrete or on the bond strength of
steel to concrete. Grouting shall conform to these
specifications or as directed by the Engineer.
In the case of external prestressing, steel shall

be encased in suitable polyethelene pipes before
grouting.
1804.6. Sheathing
The joints of all sheathings shall be water-

tight. Special attention shall be paid to the junction at
the anchorage end, where the sheathing must tightly
fit on the protruding trumpet end of anchorage and
thereafter sealed preferably with heat shrink tape, to
make it waterproof.
The heat-shrink tape is supplied in the form

of bandage rolls which can be used for all diameters
of sheathing ducts. The bandage is coated on the
underside with a heat sensitive adhesive so that after
Page 1003 of 1427

heating the bandage material shrinks on the
sheathing duct and ensures formation of a leak-proof
joint. The heating is effected by means of a soft gas
flame.
A sheath making machine should be

positioned at the site of work for large projects so
that sheathing can be prepared as and when it is
required for construction.
The sheathing and all joints shall be water

tight. Any temporary opening in the sheathing shall
be satisfactorily plugged and all joints between
sheathing and any other part of the prestressing
system shall be effectively sealed to prevent entry of
mortar, dust, water or other deleterious matter.
Sheathing shall be neatly fitted at joints without
internal projection or reduction of diameter.
Enlarged portions of the sheathing at

couplings or anchorages shall be of sufficient length
to provide for the extension of the tendons.
1804.7. Grout Vents
Grout vents of at least 20 mm diameter shall

be provided at both, ends of the sheathing and at all
valleys and crests along its length. Additional vents
with plugs shall also be provided along the length of
sheathing such that the spacing of consecutive vents
do not exceed 20 m. Each of the grout vents shall be
provided with a plug or similar device capable of
Page 1004 of 1427

withstanding a pressure of 1.0 MPa without the loss
of water, air pressure or grout.
1804.8 Anchorages
All bearing surfaces of the anchorages shall

be cleaned prior to concreting and tensioning.
Anchor cones, blocks and plates shall be

securely positioned and maintained during
concreting such that the centre line of the duct passes
axially through the anchorage assembly.
The anchorages shall be recessed from the

concrete surface by a minimum cover of 100 mm.
After the prestressing operations are

completed and prestressing wires/strands are cut, the
surface shall be painted with two coats of epoxy of
suitable formulation having a dry film thickness of
80 microns per coat and entire recess shall be
filled with concrete or non-shrink/pre-packaged
mortar or epoxy concrete.
1804.9. Structural Concrete
Structural concrete shall conform to Section

1700. The formwork shall conform to Section 1500.
1805. SUPERVISION
All prestressing and grouting operations shall
Page 1005 of 1427

be undertaken by trained personnel only. A
representative of supplier of the prestressing system
shall be present during all tensioning and grouting
operations and shall ensure, monitor and certify their
correctness.
1806. TENSIONING EQUIPMENT
All tensioning equipment shall be procured

from authorised manufacturers only and be approved
by the Engineer prior to use. Where hydraulic jacks
are used, they shall be power-driven unless
otherwise approved by the Engineer. The tensioning
equipment shall satisfy the following requirements :
(i) The means of attachments of the
prestressing steel to the jack or any
other tensioning apparatus shall be safe
and secure.
(ii) Where two or more wires/strands
constitute a tendon, a single multipull
stressing jack shall he used which is
capable of tensioning simultaneously
all the wires/ strands of the tendon.
Suitable facilities for handling and
attaching the rnultipull jack to the
tendons shall be provided.
(iii) The tensioning equipment shall be such
that it can apply controlled total force
gradually on the concrete without
inducing dangerous secondary stresses
in steel, anchorage or concrete; and
(iv) Means shall be provided for direct
Page 1006 of 1427

measurement of the force by use of
dynamometers or pressure gauges
Tilted in the hydraulic system itself to
determine the pressure in the jacks.
Facilities shall also be provided for the
linear measurement of the extension of
prestressing steel to the nearest mm and
of any slip of the gripping devices at
transfer.
All dynamo meters and pressure gauges

including a master gauge shall be calibrated by an
approved laboratory immediately prior to use and
then at intervals not exceeding 3 months and the true
force determined from the calibration curve.
Pressure gauges shall be concentric scale

type gauges accurate to within two per cent of their
full capacity. The minimum nominal size of gauge
shall be 100 mm. The gauge shall be so selected that
when the tendon is stressed to 75 per cent of its
breaking load, the gauge is reading between 50 per
cent and 80 per cent of its full capacity.
Suitable safety devices shall be fitted to

against sudden release of pressure.
Provision shall be made for the attachment of

the master gauge to be used as a check whenever
requested for by the Engineer.
1807. POST-TENSIONING
Page 1007 of 1427

Tensioning force shall be applied in gradual
and steady steps and carried out in such a manner
that the applied tensions and elongations can be
measured at all times. The sequence of stressing,
applied tensions and elongations shall be in
accordance with the approved drawing or as .
It shall be ensured that in no case, the load is

applied to the concrete before it attains the strength
specified on the drawing or as stipulated by the
prestressing system supplier, whichever is more.
After prestressing steel has been anchored,

the force exerted by the tensioning equipment shall
be decreased gradually and steadily so as to avoid
shock to the prestressing steel or anchorage.
The tensioning force applied to any tendon

shall be determined by direct reading of the pressure
gauges or dynamo-meters and by comparison of the
measured elongation with the calculated elongation.
The calculated elongation shall be invariably
adjusted with respect to the modulus of elasticity of
steel for the particular lot as given by the
manufacturer.
The difference between calculated and

observed tension and elongation during prestressing
operations shall be regulated as follows:
Page 1008 of 1427

a) If the calculated elongation it reached
before the specified gauge pressure is
obtained, continue tensioning till attaining
the specified gauge pressure, provided the
elongation does not exceed 1.05 limes the
calculated elongation. If 1.05 times the
calculated elongation is reached before the
specified gauge pressure is attained, stop
stressing and inform the Engineer.
b) If the calculated elongation has not been
reached at the specified gauge pressure,
continue tensioning by intervals of 5
kg/sq. c.m. until the calculated elongation
is reached provided the gauge
pressure does not exceed l.05 times
the specified gauge pressure.
c) If die elongation at 1 .05 times the
specified gauge pressure a less than
0.95 times the calculated elongation,
the following .measures must be taken. in
succession, to determine the cause of this
lack of discrepancy :
i) Check the correct functioning of the
jack, pump and leads.
ii) Detension the cable. Slide it in its duct
to check that h is not blocked by mortar
which has entered through holes in
the sheath. Retension the cable if free.
iii) Re ‘establish the modulus of elasticity
of steel for the particular lot from an a
proved laboratory.
Page 1009 of 1427

If the required elongation is still not obtained,
further finishing operations such as cutting or
sealing, should not be undertaken without the
d) When stressing from one end only, the

slip at the end remote from the jack shall
be accurately measured and an
appropriate allowance made in the
measured extension at the jacking end.
A complete record of prestressing operations

along with elongation and jack pressure data shall be
maintained in the format given in Appendix 1800/II.
The number of stages of prestressing and grouting
shall be reduced to a minimum, preferably 2 in the
case of simply supported girders.
1808. GROUTING OF PRESTRESSED

TENDONS
Grouting shall conform to Appendix 1800/III.

A record of grouting operations shall be maintained
in the format given in Appendix 1800/ IV.
1809. PRE-TENSIONING
1809.1. General
The planning and construction aspects of the

tensioning bed, tensioning bench, abutments at
location of anchorage, steam curing system,
Page 1010 of 1427

formwork of the concrete elements and arrangements
for demoulding, lifting, stacking and transportation
of the pre-tensioned concrete elements are all
specialised items and shall be entrusted to engineers
specifically experienced in this type of work.
1809.2. Stressing Bed for Pre-tensioning
The abutments and bed for pre-tensioning of

tendons shall be designed to withstand the total
tensioning force.
A notice shall be displayed adjacent to the

stressing bed showing the maximum tensioning force
permitted.
Where concrete elements are cast and

prestressed individually, the stressing bench or
moulds shall be rigid enough to sustain the reaction
of the prestressing force without distortion.
In the long line method of prestressing,

sufficient locator plates should be distributed
throughout the length of the bed to ensure that the
wires are maintained in their proper position during
concreting; The moulds shall be free to slide in the
direction of their length and thus permit the transfer
of the prestressing force to all the concrete elements
along the whole line.
Sufficient space shall be left in between the

ends of concrete elements to permit access for
Page 1011 of 1427

cutting the strands/wires after transfer. Hold-downs
or deflectors shall be used for holding or deflecting
the tendons in required position firmly. Deflectors
which are in contact with the tendon shall have a
diameter not less than the tendon or 15 mm,
whichever is greater.
The tensioning force required to be applied

as stated on the drawings shall be the force
remaining in the strands/wires after all strands/wires’
have been anchored to the abutments of the stressing
bed and after the anchorage slip has already taken
place. The tensioning force shall be determined by
direct reading of the pressure gauges or dynamo-
meters and by the measured elongation after slip.
The Contractor shall submit method of

tensioning the tendons including the arrangement
and layout of prestressing beds and all tendon
deflection points to the Engineer for approval before
manufacture commences.
The Contractor shall carry out trial stressing

operations to establish the frictional resistance
offered by the hold-downs and the slip during
anchoring.
Where sheathing of pre tensioned tendons is

required to prevent bond over a specified length, it
shall consist of plastic tubing or other material
approved by the Engineer and shall be of a quality,
diameter and thickness such that bond shall be
Page 1012 of 1427

effectively prevented. The tubing shall be fastened to
the tendon in such a manner that cement mortar
cannot enter. The Engineer may order that the pull-in
of the tendon be measured during the transfer of
prestress.
The Contractor shall also submit calculations

showing that the hold-downs have been designed
and constructed to withstand concentrated loads
resulting from the application of the tensioning
force.
1809.3. Tensioning Procedure
The tensioning of the wires and strands shall

be done not too much in advance of concreting.
The tensioning force shall be applied

gradually and uniformly.
In order to remove slack and to lift tendons

off the bed floor, an initial force approved by the
Engineer shall be applied to the tendons. Allowance
shall be made for this force in calculating the
required elongation.
Tendons shall be marked for measurement of

elongation after the initial force has been applied.
When required by the Engineer, tendons shall be
marked at both the jacking end and dead end of the
stressing bed and at couplers if used so that slip and
draw-in may be measured.
Page 1013 of 1427

Where deflected strands have been specified,
the Engineer may direct the elongation or strain
gauge measurements be taken at various positions
along the tendon to determine the force in the tendon
at those positions.
1809.4. Transfer of Prestress
While the process of tensioning can be

accomplished by means of hydraulic jacks, some
positive mechanical means shall be provided to
maintain the tension during the entire period
between the tensioning of the wires/strands and
transfer of the prestressing force to the concrete
element.
Transfer of prestress shall not proceed until

the Engineer has approved the proposed method.
Tendons and deflection devices shall be released in
such a pre-determined order that unacceptable tensile
stresses are not induced in the concrete.
Prior to transfer of the force to the units, all

tendons shall be tested for tightness and any loose
tendon shall be reported to the Engineer who will
decide whether the units affected shall be rejected.
The Engineer may require that tendons be

marked at each end of any unit to allow
measurement of the pull-in of the concrete.
Page 1014 of 1427

Tendons shall be released gradually and
preferably simultaneously. Under no circumstances
shall tendons be cut while under tension.
On completion of the transfer of prestress,

the projecting lengths of tendon shall be cut off flush
with the end surface of the unit, unless otherwise
shown, by a method approved by the Engineer.
In no case shall the transfer of prestressing

force to the concrete elements take place before
concrete attains the strength specified in the
drawings. To determine the specified strength,
additional cube testing shall be undertaken at the
Contractor’s cost. In case steam curing is employed,
the cubes shall be placed in the same environment as
the concrete elements to obtain an accurate
assessment of concrete strength at the time of
transfer.
The sequence of transfer of prestressing force

shall be done strictly as indicated in the drawings
and ensuring that eccentricities of the prestressing
force in the vertical and horizontal directions of the
concrete element is a minimum during the entire
sequence.
The maximum slip of any tendon during

transfer shall not exceed 3 mm at any end of the
concrete element. In case this slip is exceeded, the
concrete element in question shall be rejected.
Page 1015 of 1427

1809.5. Protection of Ends
The exposed ends of the tendons and the

concrete surfaces of the ends of the units shall be
wire brushed clean of all rust, loose mortar, grease
and din.
The exposed ends of the tendons and

concrete surface within 50 mm’ of tendons shall be
then abraded to provide a clean sound surface. An
epoxy tar paint suitably formulated to give a dry film
thickness of 80 microns per coat shall then be
immediately applied over the ends of the tendons
unless otherwise directed.
A second coat of paint shall be applied prior

to the drying out of the first coat.
1810. SAFETY PRECAUTIONS DURING

TENSIONING
Care shall be taken during tensioning to

ensure the safety of all persons in the vicinity.
Jacks shall be secured in such a manner that

they will be held in position, should they lose their
grip on the tendons.
No person shall be allowed to stand behind

the jacks or close to the line of the tendons while
tensioning is in progress.
Page 1016 of 1427

The operations of the jacks and the
measurement of the elongation and associated
operations shall be carried out in such a manner and
from such a position that the safety of all concerned
is ensured.
A safety barrier shall be provided at both

ends to prevent any tendon, which might become
loose from recoiling unchecked.
During actual tensioning operation, warning

sign shall be displayed at both ends of the tendon.
After prestressing, concrete shall neither be

drilled nor any portion cut nor chipped-away nor
disturbed, without express approval of the
Engineer.
No welding shall be permitted on or near

tendons nor shall any heat be applied to tendons.
Any tendon which has been affected by welding,
weld spatter or heat shall be rejected.
1811. TRANSPORTATION AND STORAGE OF

UNITS
Precast girders shall be transported in an

upright position. Points of support and the direction
of reactions with respect to the girder shall
approximately be the same during transportation,
and storage as when the girder is placed in final
position.
Page 1017 of 1427

When members are to be stacked, they shall
be firmly supported at such bearing positions as will
ensure that the stresses induced in them are always
less than the permissible design stresses. Further,
inclined side supports shall be provided at the ends
and along the length of a precast girder to prevent
lateral movements or instability.
Care shall be taken during storage, hoisting

and handling of the precast units to prevent their
cracking or being damaged. Units damaged by
improper storing or handling shall be replaced by the
Contractor at his expense
1812. TOLERANCES
Permissible tolerances for positional

deviation of Prestressing tendons shall be limited to
the following
a) Variation from the specified horizontal

profile : 5 mm
b) Variation from the specified vertical
profile : 5 mm
c) Variation from the specified position in
member : 5 mm

ACCEPTANCE
Page 1018 of 1427


Prestressed Concrete shall be measured in

cubic metres. The volume occupied by mild steel
reinforcement/HYSD bars, high tensile steel,
sheathing and anchorages shall not be deducted.
High tensile (prestressing) steel shall be paid

for separately and its length shall be measured as
actually incorporated in the finished work.
From the length so measured its weight -shall

be calculated in tonnes on theoretical basis and paid
for.
Anchorage devices, additional length of
cables for attaching jack, ducts or sheathing, grout,
non-prestressed steel reinforcement fixed to the
anchorage devices, making of recesses and filling the
same, protection by painting with epoxy and
furnishing samples for testing shall all be deemed to
be included in the item of high tensile steel and shall
not be measured separately.
1815. RATE
Page 1019 of 1427

The contract unit rate for cast-in-place
prestressed concrete shall cover the cost of all
materials, labour, tools and plant required for
mixing, placing in position, vibrating and
compacting, finishing as per directions of the
Engineer, curing and other incidental expenses for
producing concrete of specified strength to complete
the structure or its components as shown on the
drawings and according to specifications. The
contract unit rate shall also include the cost of
making, fixing and removing of all centring and
forms required for the work unless otherwise
For precast prestressed concrete members,

the rate in addition to above shall also include the
cost of all materials, labour, tools and plant required
to transport and place these members in their final
position as shown on the drawings and as directed by
the Engineer.
The contract unit rate for high tensile steel

shall cover the cost of material, labour, tools and
plant required for manufacturing, placing,
tensioning, anchoring and grouting the high tensile
steel in the prestressed concrete as shown on. the
drawings and as per specifications herein above or as
The cost of anchorage devices, additional

length of cables for attaching jack, ducts or
sheathing, grout, non-prestressed steel reinforcement
Page 1020 of 1427

fixed to the anchorage devices, making of recesses
and filling the same, protection by painting with
epoxy and furnishing samples for testing shall all be
included in the unit rate. Rate shall also include
payments if any to be made to the supplier of the
prestressing system who has to monitor, ensure and
certify the correctness of all operations.
Page 1021 of 1427

Structural Steel
1900
Structural Steel
Page 1022 of 1427

1901. DESCRIPTION
This work shall include furnishing,

fabricating, transporting, erecting and painting
structural steel, rivet steel, cast steel, steel forgings,
cast iron and other incidental metal construction of
the kind, size and quantity in conformity with the
drawings and these specifications or as desired by
the Engineer.
1902. GENERAL
General requirements relating to the supply

of material shall conform to the specifications of IS:
1387, for the purpose of which the supplier shall be
the Contractor and the purchaser shall be the
Engineer.
Finished rolled material shall be free from

cracks, flaws, injurious seams, laps, blisters, ragged
and imperfect edges and other defects. It shall have a
smooth and uniform finish, and shall be straightened
in the mill before shipment. They shall also be free
from loose mill scale, rust, pits or other defects
affecting its strength and durability.
The acceptance of any material on inspection

at the mill i.e. rolling mills, foundry or fabricating
plant where material for the work is manufactured,
shall not be a bar to its subsequent rejection, if found
defective
Page 1023 of 1427

Unless specified otherwise, high tensile steel
rivet conforming to IS: 1149 shall be used for
members of high tensile steel conforming to IS:961
and shall not be used for mild steel members.
Unless specified otherwise, bolted

connection of structural joints using high tensile
friction grip bolts shall comply with requirements of
IS:4000.
Cast iron shall not be used in any portion of

the bridge structure, except where it is subject to
direct compression.
1903. MATERIALS
1903.1. All materials shall conform to

Section 1000. Special requirements are given below :
Mild steel for bolts and nuts shall conform to

IS:226 but have a minimum tensile strength of 44
kg/sq. mm. and minimum percentage elongation of
14. High tensile steel for bolts and nuts shall
conform to IS:961 but with a minimum tensile
strength of 58 kg/sq. mm. High strength friction grip
bolts shall be permitted for use only on satisfactory
evidence of performance to the requirements (not
covered by these specifications) specified by the
Engineer or included in the special provisions.
For cast steel, the yield stress shall be

determined and shall not be less than 50 per cent of
Page 1024 of 1427

the minimum tensile strength.
Plain washers shall be of steel. Tapered or-

other specially shaped washers shall be of steel, or
malleable cast iron.
Parallel barrel drifts shall have a tensile

strength not less than 55 kg/sq.mm. with elongation
of not less than 20 per cent measured on a gauge
length of 4 So (So = cross sectional area).
1903.2. Materials for castings and forgings,

fasteners and welding consumables shall be as under
:
1903.2.1. Castings and Forgings : Steel

castings and forgings shall comply with the
requirements of the following Indian Standards, as
appropriate :
IS: 1030 Carbon Steel Castings for

General Engineering purposes
IS: 1875 Carbon Steel Billets, blooms,

slabs, bars for forgings
IS:2004 Carbon Steel Forgings for General

Engineering purposes
1S:2644 High Tensile Steel Casings
IS:4367 Alloy & tool steel forgings for
Page 1025 of 1427

general industrial use
1903.2.2. Fasteners : Bolts, nuts, washers

and rivets shall comply with the following or
relevant IS Standards as appropriate :
15:1929 Hot forged steel rivets for hot

closing (12-36mm dia)
IS:2155 Cold forged steel rivets for hot

closing (6-16mm dia)
IS: 1363 Hexagon head bolts, screw and

nuts product grade C
IS: 1364 Hexagon head bolts, screw &

nuts product grade A & B
IS: 1367 Technical supply conditions for

threaded steel fastener (Parts 1 to 18)
IS:3640 Hexagon fit bolts
IS:3757 High tensile friction grip bolts
IS:6623 High strength structural nuts
IS:6639 Hexagon bolls for steel structure
IS:5624 Foundation bolts
IS:7002 Prevailing torque type steel
Page 1026 of 1427

hexagon lock nuts
IS:5369 Plain washers and lock washers -

general requirements
IS:5370 Plain washers with outside dia =

.3 X inside dia
IS:5372 Taper washers for channels

(ISMC)
IS:5374 Taper Washers for I beams

(ISMB)
IS:6610 Heavy washers for steel structures
IS:6649 Hardened and tempered washers

for high strength structural bolts and nuts
1903.2-3. Welding consumables
Welding consumables shall comply with the

following Indian Standards as appropriate :
IS:814 Covered Electrodes for Metal Arc

Welding of structural (Part 1) steel for
welding other than sheets
IS:814 For welding sheets (Part 2)
IS: 1278 Filler rods and wires for gas

welding
Page 1027 of 1427

IS: 1395 Low and medium alloy Steel
covered electrodes for manual Metal Arc
Welding
IS:3613 Acceptance Tests for wire flux

combinations for submerged arc welding of
structural steel
IS-7280 Bare wire electrodes for gas shielded

arc welding of structural steel
IS:6419 Welding rods and bare electrodes for

gas shielded arc welding of structural steel
IS:6560 Molybdenum and chromium-

molybdenum low alloy steel welding rods
and bare electrodes for gas shielded arc
welding
1903.3. In aggressive environment,

corrosion resistant steel can be used. These are low-
alloyed steels containing a total of 1 per cent - 2 per
cent alloys, in particular, copper, chromium, nickel
and phosphorous.
1903.4. Paints
All materials for paints and enamels shall

conform to the requirements specified on the
drawings or other special provisions laid down by
the Engineer.
Page 1028 of 1427

The type of paints which can be used shall be
as follows :
a) Ordinary i.e. paints based on drying

oils, alkyd resin, modified alkyd resin,
phenolic varnish epoxy
b) Chemical Resistant - one pack type

(ready for use) and two pack type
(mixed before use).
c) Vinyl
d) Chlorinated rubber
e) Bituminous
f) Epoxy
g) Polyurethane
h) Zinc rich
Unless otherwise specified, paints shall

conform to the relevant IS specifications. The paints
which have been tested for the following qualities as
per specifications given in the relevant IS codes only
shall be used :
 Weight test (weight for 10 litre of

paint, thoroughly mixed)
 Drying time
Page 1029 of 1427

 Consistency
 Dry thickness and rate of
consumption.
1904. FABRICATION
1904.1. General
All work shall be in accordance with the

drawings and as per these specifications with care
being taken that all parts of an assembly fit
accurately together. All members shall carry mark
number and item number and, if required, serial
number.
Unless specifically required under the

contract, corresponding parts need not be
interchangeable, but the parts shall be match marked
as required under Clause 1904.7.
Templates, jigs and other appliances used for

ensuring the accuracy of the work shall be of mild
steel; where specially required, these shall be bushed
with hard steel. All measurements shall be made by
means of steel tape or other device properly
calibrated. Where bridge materials have been used as
templates for drilling, these shall be inspected and
passed by the Engineer before they are used in the
finished structure.
All structural steel members and parts shall

have straight edges and blunt surfaces. If necessary,
Page 1030 of 1427

they shall be straightened or flattened by pressure
unless they are required to be of curvilinear forms.
They shall also be free from twist. Pressure applied
for straightening or flattening shall be such as would
not injure the materials. Hammering shall not be
permitted. Adjacent surfaces or edges shall be in
close contact or at uniform distance throughout.
The Contractor shall submit his programme

of work to the Engineer for his approval at least 15
days before the commencement of fabrication. This
programme shall include the proposed system of
identification and erection marks together with
complete details of fabrication and welding
procedures.
The Contractor shall prepare shop drawings

for fabricating any member and obtain approval of
the Engineer before the start of work. Complete
information regarding the location, type, size and
extent of all welds shall be clearly shown on the
shop drawings. These drawings shall distinguish
between shop and field welds.
1904.2. Preparation of Edges and Ends
All structural steel-parts, where required,

shall be sheared, cropped, sawn or flame cut and
ground accurately to the required dimension and
shape.
End/edge planning and cutting shall be done
Page 1031 of 1427

by any one of the following prescribed methods or
left as rolled :
a) Shearing, cropping, sawing, machining,

machine flame culling.
b) Hand flame outline with subsequent
grinding to a smooth edge.
c) Sheared edges of plate not more than
16 mm thick with subsequent
grinding to smooth profile, which are
for secondary use such as stiffeners
and gussets.
If ends of stiffeners are required to be fitted,

they shall be ground, so that the maximum gap over
60 percent of the contact area does not exceed 0.25
mm.
Where flame cutting or shearing is used, at

least one of the following requirements shall be
satisfied.
a) The cut edge is not subjected to applied

stress.
b) The edge is incorporated in weld.
c) The hardness of cut edge does not
exceed 350 HV30.
d) The material is removed from edge to
the extent of 2 mm or minimum
necessary, so that the hardness is less
than 350 HV 30.
e) Edge is suitably heat treated by
Page 1032 of 1427

approved method to the satisfaction of
the Engineer and shown that cracks had
not developed by dye penetrant or
magnetic panicle test.
f) Thickness of plate it less than 40 mm
for machine flame dating for materials
conforming to 15:726 and IS:2062. The
requirement of hardness below 350 HV
30 of flame cut edges should be
specified by the Engineer.
Wherever specified by the Engineer, the

flame cut edges shall be ground or machined over
and above the requirement (a) to (f).
Where machining for edge preparation in butt
joint is specified, the ends shall be machined after
the members have been fabricated.
Outside edges of plate and section, which are

prone to corrosion shall be smoothed by grinding or
filing.
In the case of high tensile steel at least 6 mm

of the material from the flame cut edge shall be
removed by machining.
Longitudinal edges of all plates and cover

plates in plate girders and built-up members shall be
machined except in the following cases :
a) Rolled edges of single universal plates
or flats may not be machined.
b) Coven to single flange plates may be
Page 1033 of 1427

left unmachined.
c) Machine flame culling instead of
machining is acceptable for edges of
single plates in compression and for
edges of single plates, 25 mm or less
thick, in tension.
d) Edges of single shaped plates over 25
mm thick not capable of being
machined by ordinary method may be
machine flame cut and the end surface
ground.
e) Edges of universal plates or flats of the
same nominal width used in liers may
be left unmachined, if so authorised by
the Engineer.
All edges of splice and gusset plates 12 mm

thick and over shall be machined and those less than
12 mm thick may be sheared and ground.
The ends of plates and sections forming the

main components of plate girders or of built-up
members shall be machined, machine flame cut,
sawn or hand flame cut and ground.
Where ends of stiffeners are required to be

fitted, they shall be machined, machine flame cut,
sawn, sheared and ground, or hand flame cut and
ground.
The ends of lacing bar shall be rounded

unless otherwise required.
Page 1034 of 1427

Other edges and ends of mild steel parts may
be sheared and any burrs at edges shall be removed.
1904.3. Preparation of Holes
1904.3.1. Drilling and punching : Holes for

rivets, black bolts, high strength bolts and
countersunk bolts/rivets (excluding close tolerance
and turn fitted bolts) shall be either punched or
drilled. The diameter of holes shall be 1.5 mm
larger for bolts/rivets less than 25 mm dia and 2.0
mm for more than or equal to 25 mm.
All holes shall be drilled except for

secondary members such as, floor plate, hand rails
etc. Members which do not carry the main load can
be punched subject to the thickness of member not
exceeding 12 mm for material conforming to IS:226.
Holes through more than one thickness of

material or when any of the main material thickness
exceeds 20 mm for steel conforming to IS:2062 or
16 mm for steel conforming to IS:961, IS:8500, shall
either be sub-drilled or sub-punched to a diameter of
3 mm less than the required size and then reamed to
the required size. The reaming of material more man
one thickness shall be done after assembly.
Where several plates or sections form a

compound member, they shall, where practicable, be
firmly connected together by clamps or tacking
Page 1035 of 1427

bolts, and the holes be drilled through the group in
one operation. Alternatively, and in the case of
repetition work, the plates and sections may be
drilled separately from jigs and templates. Jigs and
templates shall be checked at least once after every
25 operations. All burrs shall be removed.
In the case of repetition of spans, the erection

of every span shall not be insisted upon, except
where close tolerance or turned bolts are used,
provided that methods are adopted to ensure strict
interchange ability. In such cases, one span in ten or
any number less than ten of each type shall be
erected from pieces selected at random by the
Engineer and should there be any failure of the
pieces to fit, all similar spans shall be erected
complete. In the event of spans being proved
completely interchangeable, all corresponding parts
shall carry the same mark so that sorting of the
materials at site is facilitated.
1904.3.2. Block drilling : Where the number

of plates to be riveted exceeds three or the total
thickness is 90 mm or more, the rivet holes, unless
they have been drilled through steel bushed jigs,
shall be drilled out in place 3 mm all round after
assembling. In such cases, the work shall be
thoroughly bolted together.
19043.3. Size of holes : The sizes of holes in

millimeters are given in Table 1900-1 below:
Page 1036 of 1427

TABLE 1900-1 : DIAMETER OF HOLES FOR
RIVETS
Nominal dia of Rivets (mm) Dia of Hole

12 13.5
14 15.5
16 17.5
18 19.5
20 21.5
22 23.5
24 25.5
27 29.0
30 32.0
33 35.0
1904.3.4. Close tolerance boits and barrel

bolts : Holes for close tolerance and turn fitted bolts.
The diameter of the holes shall be equal to the
nominal diameter of the bolt shank minus 0.15
mm to 0.0 mm.
The members to be connected with close

tolerance or turn fitted bolts shall be firmly held
together by service bolts or clamped and drilled
through all thicknesses in one operation and
subsequently reamed to required size within
specified limit of accuracy as specified in 18:919
tolerance grade H8.
The holes not drilled through all thicknesses

at one operation shall be drilled to smaller size and
Page 1037 of 1427

reamed after assembly.
1904.3.5. Holes for high strength friction

grip bolts : All holes shall be drilled after removal
of burrs. Where the number of plies in the grip
does not exceed three, the diameters of holes shall
be 1.6 mm larger than those of bolts and for more
than three plies in grip, the diameters of hole in outer
plies shall be as above and dia of holes in inner plies
shall not be less than 1.6 mm and not more
than 3.2 mm larger than those in bolts, unless
otherwise specified by the Engineer.
1904.3.6. Removal of burrs : The work

shall be taken apart after drilling and all burrs left
by drilling and the sharp edges of all rivet holes
completely removed.
1904.4. Rivet and Riveting
The diameter of rivets shown on the

drawings shall be the size before heating. Each rivet
shall be of sufficient length to form a head of the
standard dimensions as given in IS handbook on
Steel Sections, Part I. It shall be free from burrs on
the underside of the head.
When countersunk heads are required, the

heads shall fill countersunk. The included angle of
the head shall be as follows :
a) For plates over 14 nun thickness
Page 1038 of 1427

90 degrees
b) For plates upto and including 14 mm
thickness 120 degrees
The tolerance on the diameter of rivets shall

be in accordance with IS: 1148- and IS: 1149 for
mild steel rivets and high tensile steel rivets
respectively and unless otherwise specified, the
tolerance shall be minus tolerance.
Rivets shall be driven when hot so as to fill

the hole as completely as possible and shall be of
sufficient length to ~ form a head of standard
dimension. When counter-sunk head is required, the
head shall fill the counter-sunk hole. Projection after
counter-sinking shall be ground off wherever
necessary.
Rivets shall be heated uniformly to a “light

cherry red” colour between 650 degrees Celsius to
700 degrees Celsius for hydraulic riveting and
“orange colour” for pneumatic riveting of mild steel
rivets and shall be red hot from head to the point
when inserted and shall be upset in its entire length
so as to fill the hole as completely as possible when
hot Rivets, after being heated and before being
inserted in the hole shall be made free from scale by
striking the hot rivet on a hard surface.
Wherever possible, the rivets shall be

machine driven, preferably by direct acting riveters.
The driving pressure shall be maintained on the
Page 1039 of 1427

rivets for a short time after the upsetting is
completed. High tensile steel rivets shall be heated
upto 1100 degrees Celsius. Any rivet whose point is
heated more than prescribed, shall not be driven.
Where flush surface is required, any

projecting metal shall be chipped or ground off.
Before riveting is commenced, all work shall

be properly bolte up so that the various sections and
plates are in close contact throughout Drifts shall
only be used for drawing the work into position and
shall not be used to such an extent as to distort the
holes. Drifts of a larger size than the nominal
diameter of the hole shall not be used. The riveting
shall be done by hydraulic or pneumatic machine
unless otherwise specified by the Engineer.
Driven rivets, when struck sharply on the

head by a quarter pound rivet testing hammer, shall
be free from movement and vibrations. Assembled
riveted joint surfaces, including those adjacent to the
rivet heads, shall be free from scale, dirt, loose scale,
burrs, other foreign materials and defects that would
prevent solid seating of parts.
All loose or burnt rivets and rivets with

cracked or badly formed defective heads or with
heads which are unduly eccentric with the shanks,
shall be removed and replaced. In removing rivets,
the head shall be sheared off and the rivet punched
out so as not to injure the adjacent metal and, if
Page 1040 of 1427

necessary, they shall be drilled out. Recupping or
recaulking shall not be permitted. The parts not
completely riveted in the shop shall be secured by
bolts to prevent damage during transport and
handling.
1904.5. Bolts, Nuts and Washers
1904.5.1. Black bolts (black all over):

Black bolts are forged bolts in which the shanks,
heads and nuts do not receive any further treatment
except cutting of screw threads. They shall be true
to shape and size and shall have the standard
dimensions as shown on the drawings.
1904.5.2. Close tolerance bolts : Close

tolerance bolts shall be faced under the head and
turned on the shank.
1904.5.3. Turned barrel bolts : The

diameter of the screwed portion of turned barrel
bolts shall be 1.5 mm smaller than the diameter of
the barrel unless otherwise specified by the
Engineer. The diameter of the bolts as given on the
drawing shall be the nominal diameter of the barrel.
The length of the barrel shall be such that it bears
fully on all the parts connected. The threaded portion
of each bolt shall project through the nut by at least
one thread. Faces of heads and nuts bearing on steel
work shall be machined.
1904.5.4. High strength friction bolts and
Page 1041 of 1427

bolted connections: The general requirement shall
be as per relevant IS specifications mentioned in
clause 5.3 of (Fasteners) of IRC24. Unless otherwise
specified by the Engineer, bolted connections of
structural joints using high tensile friction grip bolts
shall comply with requirements mentioned in
IS:4000.
1904.5.5. Washers : In all cases where

the full bearing area of the bolt is to be developed,
the bolt shall be provided with a steel washer under
the nut of sufficient thickness to avoid any threaded
portion of the bolt being within the thickness of the
parts bolted together and to prevent the nut when
screwed up, from bearing on the bolt
For close tolerance or turned barrel bolts,

steel washers whose faces give a true bearing shall
be provided under the nut. The washer shall have a
hole diameter not less than 1.5 mm larger than the
barrel and a thickness of not less than 6 mm so that
the nut when screwed up, will not bear on the
shoulder of the bolt.
Taper washers with correct angle of taper

shall be provided under all heads and nuts bearing on
beveled surfaces.
Spring washers may be used under nuts to

prevent slackening of the nuts when excessive
vibrations occur.
Page 1042 of 1427

Where the heads or nuts bear on timber,
square washers having a length of each side not less
than three times the diameter of bolts or round
washers having a diameter of 3V2 times the diameter
of bolts and with a thickness not less than .one
quarter of diameter shall be provided.
1904.5.6. Studs : Ordinary studs may be

used for holding parts together, the holes in one of
the parts being tapped to take the thread of the stud.
Counter-sunk studs may be used for making
connections where the surfaces are required to be
clear of all obstruction, such as protruding heads of
bolts or rivets, studs may also be welded on the steel
work in the positions required.
1904.5.7. Service bolts : Service bolts shall

have the same clearance as black bolts and where it
is required that there should be no movement prior to
final riveting, sufficient drifts or close tolerance bolts
shall be used to locate the work.
1904.5.8. Tightening bolts : Bolted

connection joints with black bolts and high strength
bolts shall be inspected for compliance of codal
requirements.
The Engineer shall observe the installation

and tightening of bolts to ensure that correct
tightening procedure is used and shall determine that
all bolts are tightened. Regardless of tightening
method used, tightening of bolts in a joint should
Page 1043 of 1427

commence at the most rigidly fixed or stiffest point
and progress towards the free edges, both in initial
snugging and in final tightening.
The tightness of bolts in connection shall be

checked by inspection wrench, which can be torque
wrench, power wrench or calibrated wrench.
Tightness of 10 per cent bolts, but not less

than two bolls, selected at random in each
connection shall be checked by applying inspection
torque. If no nut or bolt head is turned by this
application, connection can be accepted as properly
tightened, but if any nut or head has turned all bolts
shall be checked and, if necessary, re-tightened.
1904.5.9. Drifts : The barrel shall be drawn

or machined to the required diameter for a length of
not less than one diameter over the combined
thickness of the metal through which the drifts have
to pass. The diameter of the parallel barrel shall be
equal to the nominal diameter of the hole subject to a
tolerance of +0 mm and -0.123 mm. Both ends of the
drift for a length equal to 1 and half times the
diameter of the parallel portion of the bar shall be
turned down with a taper to a diameter at the end
equal to one-half that of parallel portion.
1904.6. Pins and Pin Holes
1904.6.1. Pins : The pins shall be

parallel throughout and shall have a smooth
surface free from flaws. They shall be of
Page 1044 of 1427

sufficient length to ensure that all parts
connected thereby shall have a full bearing on
them. Where the ends are threaded, they shall be
turned to a smaller diameter at the ends for the
thread and shall be provided with a pilot nut, where
necessary, to protect the thread when being drawn to
place.
Pins more than 175 mm in length or diameter

shall be forged and annealed.
1904.6.2. Pin holes : Pin holes shall be bored

true to gauge, smooth, straight at right angles to the
axis of the member and parallel with each other,
unless otherwise required. The tolerance in the
length of tension members from outside to outside of
pin holes and of compression members from inside
to inside of pin holes shall be one millimeter. In
built-up members, the boring shall be done after the
members have been riveted or welded.
The specified diameter of the pin hole shall

be its minimum diameter. The resulting clearance
between the pin and the hole shall not be less than
0.5 mm and not more than l.0 mm.
1904.7. Shop Erection and Match

Marking
Before being dispatched, the steel work shall

be temporarily erected in the fabrication shop for
inspection by the Engineer either wholly or in such
Page 1045 of 1427

portion as the Engineer may require so that he may
be satisfied both in respect of the alignment and fit
of all connections. For this purpose, sufficient
number of parallel drifts and service bolts tightly
screwed up shall be employed. All parts shall fit
accurately and be in accordance with drawings and
specifications.
The steel work shall be temporarily

assembled at place of fabrication.
Assembly shall be of full truss or girder,

unless progressive truss or girder assembly, full
chord assembly, progressive chord assembly or
special complete structure assembly is specified by
the Engineer.
The field connections of main members of

trusses, arches, continuous beams, spans, bends,
plate girders and rigid frame assembled, aligned,
accuracy of holes and camber shall be checked by
Engineer and then only reaming of sub-size holes to
specified size shall be taken up.
After the work has been passed by the

Engineer and before it is dismantled, each part shall
be carefully marked for re-erection with
distinguishing marks and stamped with durable
markings. Drawings showing these markings
correctly shall be supplied to the Engineer.
Unloading, handling and storage of steel
Page 1046 of 1427

work as per these specifications shall be the
responsibility of the Contractor. The cost of repairs
or of rejected material, its removal and the cost of
transporting replacement material to the site shall be
borne by the Contractor.
Where close tolerance or turned barrel bolts

are used for those cases where interchangeability is
not insisted upon, each span shall be erected and
members of each span marked distinctly.
1904.8. Welding
1904.8.1. All welding shall be done with the

prior approval of the Engineer and the workmanship
shall conform to the specifications of IS:823 or other
relevant Indian. Standards as appropriate.
When material thickness is 20 nun or more,

special precautions like preheating shall be taken as
laid down in IS:823. Surfaces and edges” to be
welded shall be smooth, uniform and free from fins,
tears, cracks and other discontinuities. Surface shall
also be free from loose or thick scale, slag rust,
moisture, oil and other foreign materials. Surfaces
within 50 mm of any weld location shall be free
from any paint or other material that may prevent
proper welding or cause objectionable fumes during
welding.
The general welding procedures including

particulars of the preparation of fusion faces for
Page 1047 of 1427

metal arc welding shall be carried out in accordance
with IS:9595.
The welding procedures for shop and site

welds including edge preparation of fusion faces
shall be submitted in writing in accordance . with
Clause 22 of IS:9595 for the approval of the
Engineer before commencing fabrication and shall
also be as per details shown on the drawings. Any
deviation from above has to be approved by
Engineer. Preparation of edges shall, wherever
practicable, be done by machine methods.
Machine flame cut edges shall be

substantially as smooth and regular as those
produced by edge planning and shall be left free of
slag. Manual flame cutting shall be permitted by the
Engineer only where machine cutting .is not
practicable.
Electrodes to be used for metal arc welding

shall comply with relevant IS specifications
mentioned in IRC:24. Procedure test shall be carried
out as per IS:8613 to find out suitable wire-flux
combination for welded joint.
Assembly of parts for welding shall be in

accordance with provisions of IS:9595.
The welded temporary attachment should be
avoided as far as possible, otherwise the method of
making any temporary attachment shall be approved
by the Engineer. Any scars from temporary
Page 1048 of 1427

attachment shall be removed by cutting, chipping
and surface shall be finished smooth by grinding to
the satisfaction of the Engineer.
Welding shall not be done when the air

temperature is less than 10 degrees Celsius. Welding
shall not be done when the surfaces are moist, during
periods of strong winds or in snowy weather unless
the work and the welding operators arc adequately
protected.
1904.8.2. For welding of any particular

type of joint, welders shall qualify lo the satisfaction
of the Engineer in accordance with appropriate
welders qualification test as prescribed in any of the
Indian Standards IS:817, IS:1966, IS:1393, IS:7307
(part I), 1S:7310 (Part I) and IS:7318 (part I) as
relevant.
1904.8.3. In assembling and joining parts of

a structure or of built-up members, the procedure
and sequence of welding shall be such as to avoid
distortion and minimise shrinkage stress.
All requirements regarding pre-heating of

parent material and interpass temperature shall be in
accordance with provision of IS:9595.
1904.8.4. Peening of weld shall be carried

out wherever specified by the Engineer :
a) If specified, peening may be employed
Page 1049 of 1427

lo be effective on each weld layer
except first.
b) The peening should be carried out
after weld has cooled by light blows
from a power hammer using a round
note tool.’ Care shall be taken to
prevent scaling or flaking of weld
and base metal from over peening.
1904.8.5. Where the Engineer has specified

the butt welds are to be ground flush, the loss of
parent metal shall not be greater than that allowed
for minor surface defects. The ends of butt joints
shall be welded so as to provide full throat thickness.
This may be done by use of extension pieces, cross
runs or other means approved by the Engineer.
Extension pieces shall be removed after the joint has
cooled and the ends of the weld shall be finished
smooth and flush with the faces of the abutting
parts.
The joints and welds listed below are
prohibited type, which do not perform well under
cyclic loading.
a) Butt joints not fully welded throughout

their cross-section
b) Groove welds made from one side only
without any backing grip
c) Intermittent groove welds
d) Intermittent fillet welds
e) Bevel-grooves and j-grooves in butt
joints for other than horizon la I
Page 1050 of 1427

position.
f) Rug and slot welds
1904.8.6. The run-on and run-off plate

extension shall be used providing full throat
thickness at the end of butt welded joints. These
plates shall comply with the following requirements.
(i) One pair of “run-on” and one pair of “run-

off plates prepared from same thickness
and profile as the parent metal shall be
attached to start and finish of all butt
weld; preferably by clamps.
(ii) When “run-on” and “run-off1 plates shall
be removed by flame cutting, it should be
cut at more than 3 mm from parent metal
and remaining metal shall be removed by
grinding or by an;’ other method
1904.8.7. Welding of stud shear

connectors : The stud shear connectors shall be
welded in accordance with the manufacturer’s
instructions including preheating.
The stud and the surface to which studs are

welded shall be free from scale, moisture, rust and
other foreign material. The stud base shall not be
painted, galvanised or cadmium plated prior to
welding.
Welding shall not be carried out when
Page 1051 of 1427

temperature is below 10 degrees Celsius or surface is
wet or during periods of strong winds unless the
work and the welder is adequately protected.
The welds shall be visually free from cracks

and shall be capable of developing at least the
nominal ultimate strength of studs.
The procedural trial for welding the stud

shall be carried out when specified by the Engineer.
1904.9. Tolerances
Tolerances in dimensions of components of

fabricated structural steel work shall be specified on
the drawings and shall be subject to the approval of
the Engineer before fabrication. Unless specified, all
parts of an assembly shall fit together accurately
within tolerances specified in Table 1900-2.
A machined bearing surface, where specified

by the Engineer, shall be machined within a
deviation of 0.25 mm for surfaces that can be
inscribed within a square of side 0.5 m.
TABLE 1900-2 FABRICATION

TOLERANCES
A. INDIVIDUAL
COMPONENTS
1) Length
a) Member with both ±1 mm
Page 1052 of 1427

ends finished for
contact bearing + 0 mm
b) Individual - 2 mm
components of
members with end ±2 mm
plate connection ±3.5 mm
c) Other Members
i) Upto and
including 12 M
ii) Over 12 M
2) Width
a) Width of built-up ±3 mm
girders +0 mm
b) Deviation in the -3 mm
width of members
required to be
inserted in other
members
3) Depth +3 mm
Deviation in the depths -2 mm
of solid web and open
web girders
4) Straightness L/3000 subject to a

a) Deviation from maximum of IS nun
straightness of where L is length of
columns member
i) In elevation
ii) In plan + 5 mm
- 0 mm
L/1000 subject to a
Page 1053 of 1427

maximum of 10 mm
5) Deviation of centre line 3 mm

of web from centre line
of flanges in built-up
members at contact
surfaces
6) Deviation from flatness 0.005 d to a

of plate of webs of maximum of 2 mm
built-up member* in a where d is depth of
length equal to the depth the member
of the member
7) Tilt of flange of plate 0.005 b to a

girders minimum of 2 mm
a) At splices and where b
stiffeners, at is width of the
supports, at the top member 0.015 b to a
flanges of plate
girders and at
bearings maximum of 4 mm
b) at other places where
b is width of the
member
8) Deviation from L/1000. where L is
squareness of flange to nominal length of the
web of columns and box diagonal
girder
9) Deviation from D/500, where D is

squareness of fixed base the distance from the
Page 1054 of 1427

plate (not machined) to column axis to the
axis of column. This point under
dimension shall be consideration on the
measured parallel to the base plate
longitudinal axis of the
column at points where
the outer surface] of the
column sections make
contact with the base
plate
10) Deviation from D/1000. where D is

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

squareness of machined as defined in 9 above
ends to axes of beams or
girder
12) Ends of members 1/600 of depth of

abutting at joints through member subject to a
cleats or end plates, maximum of 1.5 mm
permissible deviation
from squareness of ends
1905. ERECTION
1905.1. General
The provisions of this item shall apply to
Page 1055 of 1427

erection of steel bridge superstructures or main
members of bridge superstructures, composed of
steel, which span between supports.
If the sub-structure and the superstructure are

built under separate contracts, the department will
provide the substructure, constructed to correct lines,
dimensions and elevations properly finished and will
establish the lines and the elevation required for
setting steel.
The Contractor shall erect the structural steel,

remove the temporary construction, and do all
the work required to complete the construction
included in the contract in accordance with the
drawings and the specifications and to the entire
satisfaction of the Engineer. 19052. Organisation and
Equipment
The Contractor shall submit erection plans

prepared by the fabricator, showing a method and
procedure of erection, compatible with the details of
fabrication.
A detailed scheme must be prepared showing

stage-wise activities, with complete drawings and
working phase-wise instructions. This should be
based on detailed stage-wise calculation and take
into account specifications and capacity of erection
equipment machinery, tools, tackles to be used and
temporary working loads as per Codal provisions.
The scheme should be based on site conditions e.g.
Page 1056 of 1427

hydrology, rainfall, flood timings and intensity, soil
and sub-soil conditions in the river bed and banks,
maximum water depth, temperature and climatic
conditions and available working space, etc.
The scheme should indicate precisely the

type of temporary fasteners to be used as also the
minimum percentage of permanent fasteners to be
fitted during the stage erection. The working
drawings should give clearly the temporary jigs,
fixtures, clamps, spacer supports, etc. Unless
otherwise provided in the contract, the contractor
shall supply and creel all necessary falsework and
staging and shall supply all labour, tools, erection
plant and other materials necessary to carry out the
work complete in all respects.
The Contractor shall supply all rivets, bolts,

nuts, washers, etc. required to complete erection at
site with an allowance for wastage, etc., of 12 ½ of
percent of the net number of field rivets, bolts,
washers required, or a minimum of five number of
each item.
Service bolts and nuts, ordinary platters,

washers and drifts for use in the erection of work
shall be supplied at 60 per cent (45 per cent bolts and
15 per cent drifts) of the number of field rivets per
span in each size (this includes wastage). A
reduction in the quantities of service bolts, etc., may
however, be specified by the Engineer if more than
one span of each type is ordered.
Page 1057 of 1427

Prior to actual commencement of erection all
equipment, machinery, tools, tackles, ropes, etc.
need to be tested to ensure their efficient working.
Frequent visual inspection is essential in vulnerable
areas to detect displacements, distress, drainages,
etc.
Deflection and vibratory tests shall be

conducted in respect of supporting structures,
launching truss as also the structure under erection
and unusual observations reviewed; looseness of
fittings are to be noted.
For welded structures, welders’ qualifications

and skill are to be checked as per standard norms,
Non-destructive tests of joints as per designer’s
directives are to be carried out.
Precision non-destructive testing instruments

available in the market should be used for noting
various important parameters of the structures
frequently and systematic record is to be kept.
Safety requirements should conform to

IS:7205, IS:7273 and IS:7269 as applicable and
should be a consideration of safety, economy and
rapidity.
Erection work should start with complete

resources mobilised as per latest approved
drawings and after a thorough survey of
Page 1058 of 1427

foundations and other related structural work. In
case of work of magnitude, maximum
mechanisation is to be adopted.
The structure should be divided into erectable

modules as per the scheme. This should be pre-
assembled in a suitable yard/platform and its
matching with members of the adjacent module
checked by trial assembly before erection.
The structure shall be set out to the required

lines and levels. The stocks and masses are to be
carefully preserved. The steelwork should be
erected, adjusted and completed in the required.
position to the specified line and levels with
sufficient drifts and bolts. Packing materials are to
be available to maintain this condition. Organised
“Quality Surveillance” checks need to be exercised
frequently.
Before starting work, the Contractor shall

obtain necessary approval of the Engineer as to the
method adopted for erection, the number and
character of tools and plants. The approval of the
Engineer shall not relieve the Contractor of his
responsibility for the safety of his method or
equipment or from carrying out the work fully in
accordance with the drawings and specifications.
During the progress of work, the Contractor

shall have a competent Engineer or foreman in
charge of the work, who shall be adequately
Page 1059 of 1427

experienced in steel erection and acceptable to the
Engineer.
1905.3. Handling and Storing of Materials
Suitable area for storage of structures and

components shall be located near the site of work.
The access road should be free from water logging
during the working period and the storage area
should be on levelled and firm ground.
The store should be provided with adequate

handling equipments e.g road mobile crane, gantries,
derricks, chain pulley blocks, winch of capacity as
required. Stacking area should be planned and have
racks, stands sleeper, access tracks, etc., and
properly lighted.
Storage should be planned to suit erection

work sequence and avoid damage or distortion.
Excessively rusted, bent or damaged steel shall be
rejected. Methods of storage and handling steel,
whether fabricated or not shall be subject to the
approval of the Engineer..
Fabricated materials are to be stored with

erection marks visible, such as not to come into
contact with earth surface or water and should be
accessible to handling equipment.
Small fitting hand tools are to be kept in

containers in covered stores.
Page 1060 of 1427

All materials, consumables, including raw
steel or fabricated material shall be stored
specification-wise and size-wise above the ground
upon platform?, skids or other supports. It shall be
kept free from dirt and other foreign matter and shall
be protected as far as possible from corrosion and
distortion. The electrodes shall be stored
specification-wise and snail be kept in dry warm
condition in properly designed racks. The bolts, nuts,
washers and other fasteners shall be stored on racks
above the ground with protective oil coating in
gunny bags. The paint shall be stored- under cover in
air-tight containers.
IS:7293 and IS:7969 dealing with handling of

materials and equipments for safe working should be
followed. Safety nuts and bolts as directed are to be
used while working. The Contractor shall be held
responsible for loss or damage to any material paid
for by the Department while in his care or for any
damage to such material resulting from his work.
1905.4. Formwork
The form work shall be properly designed,

substantially built and maintained for all anticipated
loads. The Contractor, if required, shall submit plans
for approval to the Engineer. Approval of the plans,
however, shall not relieve the Contractor of his
responsibility.
Page 1061 of 1427

1905.5. Straightening Bent Material
The straightening of plates, angles and other

shapes shall be done by methods not likely to
produce fracture or any injury. The metal shall not
be heated unless permitted by the Engineer for
special cases, when the heating shall not be to a
temperature higher than that producing a dark
“cherry red” colour, followed by as slow cooling as
possible. Following the straightening of a bend or
buckle the surface shall be carefully investigated for
evidence of fracture. Sharp kinks and bends may be
the cause for rejection of material.
1905.6. Assembling Steel
The parts shall be accurately assembled as

shown on the drawings and match marks shall be
followed. The material shall be carefully handled so
that no parts will be bent, broken or otherwise
damaged.
Hammering which will injure or distort the

members shall not be done. Bearing surface or
surfaces to be in permanent contact shall be cleaned,
before the members are assembled. The truss spans
shall be erected on blocking, so placed as to give the
proper camber. The blocking shall be left in place
until the tendon chord splices are fully riveted and
all other truss connections pinned and bolted. Rivets
in splices of butt joints of compression members and
rivets in railings shall not be driven until the span
Page 1062 of 1427

has been swung.
All joint surface for bolted connections

including bolts, nuts, washers shall be free from
scale, dirt, burrs, other foreign materials and defects
that would prevent solid seating of parts. The slope
of surface of bolted parts in contact with bolt head
and nut shall not exceed 1 in 20, plane normal to bolt
axis, otherwise suitable tapered washer shall be used.
All fasteners shall have a washer under nut or

bolt head whichever is turned in tightening.
Any connection to be riveted or bolted shall

be secured in close contact with service bolts or with
a sufficient number of permanent bolts before the
rivets are driven or before the connections are finally
bolted. Joints shall normally be made by filling not
less than 50 per cent of holes with service bolts and
barrel drifts in the ratio 4:1. The service bolts are to
be fully tightened up as soon as the joint is
assembled. Connections to be made by close
tolerance or barrel bolts shall be completed as soon
as practicable after assembly.
Any connection to be site welded shall be

securely held in position by approved methods to
ensure accurate alignment, camber and elevation
before welding is commenced.
The field riveting, welding, bolted and pin

connection shall conform to the requirements of
Page 1063 of 1427

Clause 1904 as appropriate.
The correction of minor misfits involving

harmless amounts of reaming, cutting and chipping
will be considered a legitimate pan of erection.
However, any error in the shop fabrication or
deformation resulting from handling and
transportation which prevents proper assembling and
fitting up of parts by moderate use of drifts Of by a
moderate amount of reaming and slight chipping or
cutting shall be reported immediately to the Engineer
and his approval of the method of correction
obtained. The correction shall be made in the
presence of-the Engineer.
1905.7. Field Inspection
1905.7.1. General
All materials, equipment and work of

erection shall be subject to the inspection of the
Engineer who shall be provided with all facilities
including labour and tools required at all reasonable
times. Any work found defective is liable to be
rejected.
1905.7.2. No protective treatment shall be

applied to the work until the appropriate inspection
and testing has been carried out The stage
inspection shall be carried out for all operations so as
to ensure the correctness of fabrication and good
quality. Girder dimensions and camber shall not
Page 1064 of 1427

be finally checked until all welding and heating
operations are completed and the member has
cooled to a uniform temperature.
1905.7.3. Testing of material : Structural

steel shall be tested for mechanical and chemical
properties as per various IS codes as may be
applicable and shall conform to requirements
specified in IS:226, IS:2062, IS:11587, 1S:1977,
1S:8500 and IS:961, etc.
Rivets, bolts, nuts, washers, welding

consumables, steel forging, casting and stainless
steel shall be tested for mechanical and chemical
properties in the appropriate IS Code.
Rolling and cutting tolerance shall be as per

IS: 1852. The thickness tolerance check
measurements for the plate and rolled sections shall
be taken at not less than 15 mm from edge.
Laminations in plates shall be carried out by

ultra-sonic testing of any other specified methods.
Steel work shall be inspected for surface

defects and exposed edge laminations during
fabrication and blast cleaning. Significant edge
laminations found shall be reported to the Engineer
for his decision.
Chipping, grinding, machining or ultrasonic

testing shall be used to determine depth of
Page 1065 of 1427

imperfection.
1905.7.4. Bolted connections : Bolts and

bolted connection joints with high strength
friction grip bolls shall be inspected and tested
according to IS:4000.
Rivets and riveted connection shall be

inspected and tested for compliance of codal
requirements.
The firmness of joint shall be checked by 0.2

mm filler gauge, which shall not go inside under the
rivet head by more than 3 mm. There shall not be
any gap between members to be riveted.
Driven rivets shall be checked with rivet

testing hammer. When struck sharply on head with
rivet testing hammer, rivet shall be free from
movement and vibration.
All loose rivets and rivets with cracks, badly

formed or deficient heads or with heads which are
eccentric with shanks, shall be cut out and replaced.
The alignment of plates at all bolted splice

joints and welded butt joints shall be checked for
compliance with codal requirements.
Testing of flame cut and sheared edges is to

be done, where the hardness criteria given in the
code are adopted. Hardness testing shall be carried
Page 1066 of 1427

out on six specimens.
1905.7.5. Welding and welding

consumables : Welding procedure, welded
connection and testing shall be in compliance with
codal requirements.
All facilities necessary for stage inspection

during welding and on completion shall be provided
to the Engineer or their inspecting Authority by
manufacturer.
Adequate means of identification either by

identification mark or other record shall be provided
to enable each weld to be traced to the welder(s) by
whom it was carried out.
All metal arc welding shall be in compliance

with IS:9S95 provisions.
The method of inspection shall be in

accordance with IS:822 and extent of inspection and
testing shall be in accordance with the relevant
standards or in the absence of such a standard, as
agreed with the Engineer.
Procedure tests
The Destructive and Non-Destructive test of

weld shall be carried out according to IS:7307 (Part
I).
Page 1067 of 1427

Non-Destructive Testing of Welds
One or more of the following inspection

or testing of weld :
i) Visual Inspection : All. welds shall be visually

inspected, which should cover all defects of weld
such as size, porosity, crack in the weld or in the
HAZ (Heat Affected Zone) etc. Suitable
magnifying glass may be used for visual
inspection. A weld shall be acceptable by visual
inspection if it shows that :
a) The weld has no cracks.
b) Through fusion exists between weld and base
metal and between adjacent layer of weld
metal.
c) Weld profiles are in accordance with
requisite clauses of IS:9595 or as agreed with
the Engineer.
d) The weld shall be of full cross section, except
for the ends of intermittent fillet welds
outsite their effective length.
e) When weld is transverse to the primary
stress, undercut shall not be more than 0.25
mm deep in the part that is undercut and shall
not be more than 0.8 nun deep when the weld
is parallel to the primary stress in the part
that is undercut.
f) The fillet weld in any single continuous Weld
shall be permitted to under run the nominal
fillet weld size specified by 1.6 mm without
correction provided mat unfertile portion of
Page 1068 of 1427

the weld does not exceed 10 per cent of the
length of the weld. On the web-to-flange
welds on girders, no under-run is permitted at
the ends for a length equal to twice the width
of the flange.
g) The piping porosity in fillet welds shall not
exceed one in each 100 mm of weld length
and the maximum diameter shall not exceed
2.4 mm, except for fillet welds connecting
stiffeners to web where the turn of diameters
of piping porosity shall not exceed 9.5 mm in
any 25 mm length of weld and shall not
exceed 19 mm in any 300 mm length of
weld.
h) The full penetration groove weld in butt
joints transverse to the direction of computed
tensile stress shall have no piping porosity.
For all other groove welds, the piping
porosity shall not exceed one in 100 mm of
length and the maximum diameter shall not
exceed 2.4 mm.
ii) Magnetic Panicle and Radio-graphic Inspection:

Welds that are subject to radio-graphic or
magnetic particle testing in addition to visual
inspection shall have no crack.
Magnetic particle test shall be carried out for

detection of crack and other discontinuity in the
weld according to IS:5334.
Radiographic test shall be carried out for
Page 1069 of 1427

detection of internal flaws in the weld such as
crack, piping porosity inclusion, lack of fusion,
incomplete penetration, etc. This test mat be
carried out as per IS:1182 and 15:4853.
Acceptance Criteria: The weld shall be

unacceptable if radiographic or magnetic panicle
testing shows any of the type of discontinuities
indicated in the code.
iii) Ultrasonic Inspection : The Ultrasonic testing in

addition to visual inspection shall be carried out
for detection of internal flaws in the weld such as
cracks, piping porosity inclusion, lack of fusion,
incomplete penetration, etc. Acceptance criteria
shall be as per IS:4260 or any other relevant IS
Specification and as agreed to by the Engineer.
iv) Liquid Penetration Inspection : The liquid

penetrant test shall be carried out for detection of
surface defect in the weld, as per 15:3658, in
addition to visual inspection.
The non-destructive testing of following welds
be carried out using one of the method or
methods described at (ii),(iii) and (iv) above, as
may be agreed to by the Engineer.
a) All transverse butt welds in tension flange
b) 10 per cent of the length of longitudinal and
transverse butt welds in tension flanges.
c) 5 per cent of the length of longitudinal
and transverse but welds in compression
flanges.
Page 1070 of 1427

d) All transverse butt welds in webs adjacent to
tension flanges as specified by the Engineer.
The particular length of welds in webs to be

tested shall be agreed with the Engineer, in case of
(b) or (c).
Where specified by the Engineer, bearing

stiffeners or bearing diaphragms adjacent to welds,
flange plates adjacent to web/flange welds, plates at
cruciform welds, plates in box girder construction
adjacent to corner welds or other details shall be
ultrasonically tested after fabrication.
Any lamination, lamellar tearing or other

defect found shall be recorded and reported to
Engineer for his decision.
Testing of Welding for Cast Steel : The

testing of weld for cast steel shall be carried out as
may be agreed to by the Engineer.
Stud Shear Connectors : Stud shear

connectors shall be subjected to the following tests :
i) The fixing of studs after being welded in
position shall be tested by (inking the
side of the head of the stud with a 2 kg
hammer to the satisfaction of the
Engineer.
ii) The selected stud head stroked with 6
kg hammer shall be capable of lateral
displacement of approximately 0.25 the
Page 1071 of 1427

height of the stud from its original
position. The stud weld shall not show
any sign of crack or lack of fusion.
The studs whose welds have failed the tests

given in (a) and (b) shall be replaced.
1905.7.6. Inspection requirement : The

fabricated member/component made out of rolled
and built-up section shall be checked for compliance
of the tolerances given in Table 1900-2. Inspection
of member/components for compliance with
tolerances, and the check for deviations shall be
made over the full length.
During checking, the inspection requirement

shall be placed in such a manner that local surface
irregularities do not influence the results.
For plate, out-of-plane deviation shall be

checked at right angle to the surface over the full
area of plate.
The relative cross-girder or cross frame

deviation shall be checked over the middle third of
length of the cross girder or frame between each pair
of webs and for cantilever at the end of member.
The web of rolled beam or channel section

shall be checked for cut-of-plane deviation in
longitudinal direction equal to the depth of the
section.
Page 1072 of 1427

During inspection, the component / member
shall not have any load or external restraint.
Inspection Stages : The inspection to be

carried out for compliance of tolerances shall include
but not be limited to the following stages:
a) For completed parts, component/members on

completion of fabrication and before any
subsequent operation such as surface
preparation, painting, transportation,
erection.
b) For webs of plate and box girder,
longitudinal compression flange stiffeners
in box girders and orthotropic decks and
all web stiffeners at site joints, on completion
of site joint
c) For cross girders and frames, cantilevers
in orthotropic decks and other pans in
which deviations have apparently increased
on completion of site assembly.
Where, on checking member/component for

the deviations in respect of out-of-plane or out-of-
straightness at right angles to the plate surface, and
any other instances, exceed tolerance, the maximum
deviation shall be measured and recorded. The
recorded measurements shall be submitted to the
Engineer who will determine whether the
component/member may be accepted without
rectification, with rectification or rejected.
Page 1073 of 1427

1906. PAINTING
1906.1. General
Unless otherwise specified, all metal work

shall be given approved shop coats as well as field
coats of painting. The item of work shall include
preparation of metal surfaces, application of
protective covering and drying of the paint coatings
and supply of all tools, scaffolding, labour and
materials necessary.
Coatings shall be applied only to dry surfaces

and the coated surfaces shall not be exposed to rain
or frost before they are dry. The coatings shall be
applied to all surfaces excluding shear connectors
and inner surfaces of fully sealed hollow sections.
Care shall be taken during coating of adjacent
surfaces to build up primer on the shear connectors.
1906.1.1. Types of paints

(i) Ordinary Paints
These include paints based on drying oils,

alkyd resin, modified alkyd resin, phenolic varnish
epoxy, etc.
Alkyd resin paints for the protection of steel

structures are based partly on natural oils and partly
on synthetic resins. These paints shall be used for
steel structures in atmospheres which are not too
Page 1074 of 1427

aggressive. Oil based paints can be used for steel
structures in cases where the surface preparation
cannot be ideal. Ordinary painting can generally be
sub-divided into two groups :
a) Primary Coats
This shall be applied immediately after
the surface preparation and should have
the properties of adhesion, corrosion
inhibition and imperviousness to water
and air.
b) Finishing Coats
These are applied over the primary coat and

should have the properties of durability,
abrasion resistance, aesthetic appearance and
smooth finish.
(ii) Chemical Resistant Paints
The more highly corrosion resistant paints

can be divided into two main groups :
a) One pick paints (ready: for use)
b) Two pack paints (mixed before use)
The two pack paints shall be mixed together

immediately before use since they are workable
thereafter only for a restricted period of time and dry
up as a result of a reaction between their components
and yield hard tough films with resistance to
abrasion.
Page 1075 of 1427

(iii) Vinyl Paints
These are based on polyvinyl resins such as

polyvinyl-chloride (PVC) and polyvinyl-acetate, etc.
Certain types of vinyl resin paints yield thick,

relatively soft and rubber like coatings with good
chemical resistance. They can be repainted without
difficulty.
(iv) Chlorinated Rubber Paints
These paints also have good chemical

resistance. The main fields of applications shall be in
aggressive environments. In general, chlorinated
rubber paints do not have a high gloss.
(v) Bituminous Paints
As a paint vehicle, bituminous is inferior, but

because of the low price, this should be applied in
greater thickness (upto several millimeters) and may
be suitable for some situations. A significant
advantage of bitumen paints is their impermeability
to ingress of water. However, bituminous paints do
not withstand effectively detrimental effects of oil.
(vi) Epoxy Paints
These resin paints have good adherence to a

well prepared substrata. They are mechanically
strong and resistant to chemicals. A disadvantage of
epoxy resin paints is that it can rapidly become dull
Page 1076 of 1427

when exposed to strong sunlight. These
disadvantages do not, however, greatly influence
their protective power.
(vii) Polyurethane Paints
The chemical and mechanical behaviour of

polyurethane paint resembles those of epoxy paint
very much. However, polyurethane paint retains its
gloss for a longer period. Because of the high price
of polyurethane paint, a combination of the two
viz., polyurethane and epoxy paints may sometimes
be used.
(viii) Zinc Rich Paints
Instead of introducing an inhibitive pigment

into paint, metallic zinc can-be used and such paints
can provide cathodic protection to steel.
1906.1.2. Surfaces which are inaccessible for

cleaning and painting after fabrication shall be
painted as specified before being assembled for
riveting.
All rivets, bolts, nuts, washers etc., are to be

thoroughly cleaned and dipped into boiling linseed
oil conforming to IS:77.
All machined surfaces are to be well coated

with a mixture of white lead conforming to 1S:34
and Mutton Tallow conforming to IS:887.
Page 1077 of 1427

For site paintings, the whole of the steel work
shall be given the second cover coat after final
passing and after touching up the primer and cover
coats, if damaged in transit.
1906.13. Choice of painting system
The choice of suitable painting system is

dependent on factors such as:
 Available application methods viz.

brush, roller or spray
 Durability in a specific environment
Availability of skilled manpower
 Cost / benefit etc.
It is therefore necessary to consult various

manufacturers of paint and ascertain the above
aspects while deciding on the appropriate choice of
painting system.
1906.1.4. Quality of paint : The paints

which have been tested for the following qualities as
per the specifications given in the relevant IS codes
should only be used :
 Weight Test (weight per 10 litre of
paint thoroughly mixed)
 Drying time
 Flexibility and Adhesion
 Consistency
 Dry thickness and rate of
Page 1078 of 1427

consumption
1906.1.5. Unless otherwise specified, all

painting and protective coating work shall be done in
accordance with IS: 1477 (Part 1).
1906.2. Surface Preparation
Steel surface to be painted either at the

fabricating shop or at the site of work shall be
prepared in a thorough manner with a view to
ensuring complete removal of mill scale by one of
the following processes as agreed to between the
fabricator and the Engineer :
a) Dry or wet grit / Sand blasting

b) Pickling which should be restricted to
single plates, bars and sections
c) Flame cleaning
Primary coat shall be applied as soon as

practicable after cleaning and in case of flame
cleaning, primary coal shall be applied while the
metal is still warm.
All slag from welds shall be removed before

painting. Surfaces shall be maintained dry and free
from dirt and oil. Work out of doors in frosty or
humid weather shall be avoided.
1906.3. Coatings
Page 1079 of 1427

Prime coat to be used shall conform to the
specification of primers approved by the Engineer.
Metal coatings shall be regarded as priming coatings.
Primer shall be applied to the blast cleaned surface
before any deterioration of the surface is visible. In
any case, the surface shall receive one coat of primer
within 4 hours of abrasive blast cleaning.
All coats shall be compatible with each other.

When metal coatings are used, the undercoat shall be
compatible with the metal concerned. The undercoat
arid finishing coat shall preferably be from the same
manufacturer. Successive coals of paints shall be of
different shades or colours and each shall be allowed
to dry thoroughly before the next is applied:
Particular care shall be taken with the priming and
painting of edges, corners, welds and rivets. Typical
guidelines for epoxy based paints and the
conventional painting system for bridge girders as
given below may be complied with :
a) Epoxy Based Painting
i) Surface preparation : Remove
oil/grease by use of petroleum
hydrocarbon solution (IS:1745) and
Grit blasting to near white metal
surface
ii) Paint system: 2 coats of epoxy zinc
phosphate primer = 60 micron ; Total
5 coats - 200 micron
b) Conventional Painting System for areas
where corrosion is not severe
Page 1080 of 1427

Priming Coat :
One heavy coat or ready mixed paint, red

lead primer conforming to IS:102
or
One coat of ready mixed zinc chrome primer

conforming to IS: 104 followed by one coat of ready
mixed red oxide zinc chrome primer conforming to
IS:2074.
or
Two coats of zinc chromates red oxide

primer conforming to IS:2074
Finishing Coats :
Two cover coats of red oxide paint

conforming to IS: 123 or any other approved paint
shall be applied over the primer coat One coat shall
be applied before the fabricated steel work leaves the
shop. After the steel work is erected at site, the
second coat shall be given after touching up the
primer and the cover coats if damaged in transit.
c) Conventional Painting System for

areas where corrosion is severe
Priming Coat :
Page 1081 of 1427

Two coats of ready mixed red lead primer
conforming to IS: 102
or
One coat of ready mixed zinc chrome primer

conforming to IS: 104 followed by one coat of zinc
chromate conforming oxide primer to IS:2074.
Finishing Coats :
Two coats of aluminum paint conforming to

IS:2339 shall be applied over the primer coat. One
coat shall be applied before the fabricated steel work
leaves the shop. After the steel work is erected at
site, the second coat shall be given after touching up
the primer and the cover coats if damaged in transit.
1906.4. Painting in the Shop
All fabricated steel shall be painted in the

shops after inspection and acceptance with at least
one priming coat, unless the exposed surfaces are
subsequently to be cleaned at site or are metal
coated. No primer shall be applied to galvanised
surfaces.
Shop contact surfaces, if specifically required

to be painted, shall be brought together while the
paint is still wet.
Field contact surfaces and surfaces to be in
Page 1082 of 1427

contact with cement shall be painted with primer
only. No paint shall be applied within 50mm of
designed location of field welds. Paint shall be
completely dried before loading and transporting to
site.
Surface not in contact but inaccessible after

shop assembly shall receive the fully specified
protective treatment before assembly.
Where surfaces are to be welded, the steel

shall not be painted or metal coated within a suitable
distance from any edges to be welded if the specified
paint or metal coating would be harmful to welders
or is expected to impair the quality of site welds.
Exposed machined surfaces shall be

adequately protected.
1906.5. Painting at Site
Surfaces which will be inaccessible after site

assembly shall receive the full specified protective
treatment before assembly.
Surfaces which will be in contact after site

assembly shall receive a coat of paint (in addition to
any shop priming) and shall be brought together
while the paint is still wet.
Damaged or deteriorated paint surface;; shall

be first made good with the same type of coat as the
Page 1083 of 1427

shop coat.
Where steel has received a metal coating in

the shop, this coating shall be completed on site so
as to be continuous over any welds, bolts and site
rivets.
Specified protective treatment shall be

completed after erection.
1906.6. Methods of Application
The methods of application of all paint

coatings shall be in accordance with the
manufacturer’s written recommendation and shall be
as approved by the Engineer. Spray painting may be
permitted provided it will not cause inconvenience to
the public and is appropriate to the type of structure
being coated. Areas hard to gain access to for
painting and areas shaded for spray application shall
be coated first by brushing.
Oil based red lead primers must be applied

by brush only, taking care to work into all corners
and crevices.
The primer, intermediate and finishing coats

shall all be applied so as to provide smooth coatings
of uniform thickness. Wrinkled or blistered coatings
or coatings with pinholes, sags, lumps or other
blemishes shall not be accepted. Where the Engineer
so directs, the coating shall be removed by abrasive
Page 1084 of 1427

blast cleaning and replaced at the Contractor’s
expense.
1906.7. Guideline of Specifications for

Protective Coating
System in Different Environments
Since the seriousness of the problem of

corrosion depends upon atmospheric conditions and
these vary enormously, there is no single protective
system or method of application that is suitable for
every situation.
However, as a guide, broad recommendations

are given in Table 1900-3 for various types of
coatings in various environmental conditions which
should be complied with. Approximate life to first
maintenance is also indicated and can be used as a
guide.
TABLE 1900-3 : RECOMMENDATIONS FOR

TYPES OF PROTECTIVE
COATINGS
System Environment
(i) Wire brush to remove Suitable for mild
all loose nisi and conditions where
scale; 2 coats drying appearance is of some
oil type primer, 1 importance and where
under coat alkyd type regular maintenance is
paint; 1 finishing coal intended. This system
Page 1085 of 1427

alkyd type. Total dry may deteriorate to a
film thickness = 150 marked extent if it is
µm exposed to moderate
aggressive
atmospheric conditions
for lengthy period
(ii) Wire brush to remove Similar to (i) but

all loose rust and where appearance is
scale; 2 coats drying not very important
oil type primer, 2 provides longer life in
under coals mild condition. Will
micaceous iron oxide provide upto 5 years
(MXO) pigmented life to first
phenolic modified maintenance in
drying oil. Total dry polluted inland
film thickness = 170 environment
µm
(iii) Blast clean the Compared to (i), this

surface; 2 coats of would provide a longer
quick drying primer, life in mild conditions
undercoat alkyd and could be used in
type paint; 1 less mild situation e.g.
finishing coat alkyd inland polluted, where
type. Total dry film maintenance could
thickness : 130 - 150 easily be carried out
µm at regular intervals
(iv) Blast clean the Suitable for general

surface; 2 coats of structural steel work
drying type oil exposed to ordinary
Page 1086 of 1427

primer; 1 undercoat polluted inland
micaceous iron environments where
oxide pigmented appearance is not of
drying oil type primary importance.
paint. Total dry
film thickness :
165 - 190 µm
(v) Blast clean the Suitable for structures
surface; 2 coats of in reasonably
metallic lead aggressive conditions
pigmented e.g. near the coast.
chlorinated rubber Will provide long-term
primer. 1 undercoat protection than (iv) in
of high build non-coastal situations.
chlorinated rubber; Also suitable for
1 finishing coat of aggressive interior
chlorinated rubber. situations such as
Total dry film industrial areas.
thickness : 200 µm
(vi) Blast clean the Suitable for sea water

surface; 350 – 450 splash zones or for
µm thickness, coal conditions of
tar epoxy. occurrence of frequent
salt sprays.
(vii) Pickle; hot dip Suitable for steel work

galvanized (Zinc). in reasonably mild
Total thickness : 85 conditions Life of 15-
µm 20 years before first
maintenance could be
expected in many
Page 1087 of 1427

situations
(viii) Grit blast, hot dip Provides a longer life

galvanised. (Zinc). than (vii) because of
Total thickness = thicker zinc coating
140 µm
(ix) Grit blast; 1 coat Expected to provide

of sprayed zinc/ long term protection
aluminum approx 15-20 years in
followed by aggressive atmosphere
suitable sealer
Total thickness =
150 µm

ACCEPTANCE
The materials -shall be tested in accordance

with relevant IS specifications and necessary test
certificates shall be furnished. Additional tests, if
required, shall be got carried out by the Contractor at
his own cost.
The fabrication, furnishing, creeping,

painting of structural steel work shall be in
accordance with these specifications and shall be
checked and accepted by the Engineer.
Page 1088 of 1427

PAYMENT
The measurements of this item shall be in

tonnes based on the net weight of metal in the
fabricated structure computed on the basis of
nominal weight of materials.
The weight of rolled and cast steel and cast
iron shall be determined from the dimensions shown
on the drawings on the following basis :
 Roiled or cast steel : 7.84 x 10-3

kg/cu. cm.
 Cast Iron : 7.21 x 10-3 kg/cu. cm.
Weight of structural sections shall be

nominal weight
Weight of castings shall be computed from

the dimensions shown on the drawings with an
addition of 5 per cent for fillets and over-runs.
Weight of weld fillets and the weight of

protective coatings shall . not be included.
Weight of rivet heads shall be computed by

taking the weight of 100 snap heads as given in
Table 1900-4.
When specially agreed upon, allowance for

snap heads may be taken as a flat percentage of the
total weight. This percentage may be taken as 3 per
Page 1089 of 1427

cent or modified by mutual agreement.
TABLE 1900-4 : WEIGHT OF RIVET HEADS
Dia of Rivet as Weight of 100 snap

manufactured mm heads kg
12 1.3
14 2.1
16 3.4
18 4.45
20 6.1
22 8.1
24 10.5
27 15.0
30 20.5
33 27.2
The Contractor shall supply detailed

calculation sheets for the weight of the metal in the
fabricated structure.
No additions shall be made for the weight of

protective coating or weld fillets.
Where computed weight forms the basis for

payment, the weight shall be calculated for exact cut
sizes of members used in the structure, deductions
being made for all cuts, except for rivet holes.
Additions shall be made for the rivet heads as
mentioned above.
Page 1090 of 1427

When specially agreed upon, the basis for
payment may be the bridge weight complete,
according to specifications included in special
provisions of the Contract
1909. RATE
The contract unit rate for the completed

structural steel work shall include the cost of all
materials, labour, tools, plant and equipment
required for fabrication, connections, oiling,
painting, temporary erection, inspection, tests and
complete final erection as shown on the drawings
and as specified in these Specifications.
Page 1091 of 1427

Bearings
2000
Bearings
Page 1092 of 1427

2001. DESCRIPTION

fixing bearings in position in accordance with the
details shown on the drawings, to the requirements
of these specifications or as directed by the
Engineer.
2002. GENERAL
i) Bearing plates, bars, rockers, assemblies and

other expansion or fixed devices shall be
constructed in accordance with the details
shown on the drawings.
ii) The bearings may either be supplied directly
to the Engineer by the manufacturer to be
installed by the Contractor or the Contractor
is to supply and install the bearings as part of
the contract. In the former case, the
manufacturer shall be associated with the
installation of the bearings to the full
satisfaction of the Engineer, whereas in the
latter case, the Contractor shall be solely
responsible for the satisfactory supply and
installation of the bearing. In the detailed
description of the specification, a general
reference shall be made to the Contractor or
manufacturer and the interpretation shall be
as per terms of contract
iii) The Contractor shall exercise the utmost care
in setting and fixing all bearings in their
correct positions and ensuring that uniformity
is obtained on all bearing surfaces.
Page 1093 of 1427

iv) Bearings shall be handled with care and
stored under cover.
v) When bearing assemblies or plates are shown
on the drawings to be placed (not embedded)
directly on concrete, the concrete bearing
area shall be constructed slightly above grade
(not exceeding 12 mm) and shall be finished
by grinding.
vi) It shall be ensured that the bearings are set
truly level and in exact position as indicated
on the drawings so as to have full and even
bearing on the seals. Thin mortar pads (not
exceeding 12 mm) may even be made to
meet with this requirement.
vii) It shall be ensured that the bottoms of girders
to be received on the bearings are plane at the
locations of these bearings and care shall be
taken that the bearings are not displaced
while placing the girders.
viii) M.S. bearings sliding on M.S. Plates shall not
be permitted. For sliding plate bearings
stainless, steel surface sliding on stainless
steel plate with mild steel matrix shall be
used. The other option shall be to provide
PTFE surface sliding on stainless steel.
ix) Some types of bearings which have been
successfully used in various bridges in India
have been covered by these Specifications.
For innovative types of structures or in
special cases, special types of bearings to suit
the requirements may have to be provided for
which special specifications may be laid
Page 1094 of 1427

down by the Engineer.
2003. STEEL BEARINGS 2003.1.

Materials
The material for steel bearings shall conform

to the requirements of Section 1000. Some
additional requirements for materials for steel
bearings are indicated below :
a) Railway axles (R 19) are also

acceptable as forged steel for rollers.
b) For the purpose of checking the

soundness of cast steel components,
castings shall be ultrasonically
examined following procedures as per
1S:7666 with acceptance standard as
per 15:9565. The castings may also be
checked by any other accepted method
of non-destructive testing as
specified, in IS: 1030. Quality level of
castings shall be level 3 as per 18:9565.
The grease for beatings shall conform to the

requirements of IS:503 (Grade 4).
a) All work shall conform strictly to the

drawings and shall be in accordance with
the provisions of this section. Care shall
Page 1095 of 1427

be taken to ensure that all parts of an
assembly fit accurately together. The
workmanship shall satisfy all relevant
provisions laid down in Section 1900.
b) Knuckle pins, rolling surfaces of the
rollers and bearing surface of the bearing
plates shall be machined and all bolt
holes shall be drilled. The whole bearings
shall be fitted and finished as required for
good quality machined work to the
satisfaction of the Engineer. However, in
case of bearings which are to be grouted
or bedded on .a suitable yielding material
on any surface which is to be in
permanent contact with the grout or the
yielding material may be left
unmachined.
c) In prestressed concrete construction
where launching of girders is employed,
in order to avoid slipping or jumping of
rollers due to vibration or jolts. adequate
measures may be taken to ensure that the
roller assembly is not disturbed. It is
normal practice to provide rocker
bearings on the launching end and place
the beam on the rocker end slightly in
advance of placing on the roller.
d) During concreting of girders, the bearings
shall be held in position securely by
providing temporary connection between
the top and bottom plates in case of fixed
bearings and between top plate, base
Page 1096 of 1427

plate and saddle plate in case of roller-
cum-rocker bearing or by any other
suitable arrangement which prevents the
relative displacement of the components.
e) In prestressed precast girders, where
recesses are left on the underside of
girders to receive the anchor bolts, grout
holes extending to the beam sides or to
the deck level shall be provided. The
cement sand grout shall have a mix of
1:1.
2003.3. Workmanship
a) Fabrication shall be carried out by an

organisation experienced and qualified
to undertake precision engineering of
this type and be approved by the
Engineer.
b) Workmanship shall be of good quality,
neatly finished and of good appearance.
c) Castings shall be true to the forms and
dimensions shown on the drawings
and shall be free from pouring faults,
sponginess. cracks, blow holes and
other defects on position, affecting their
appearance or strength. Warped or
distorted castings will not be accepted.
Exposed surfaces shall be smooth and
dense.
d) All castings shall be cleaned by sand
or shot blasting to remove sand or
Page 1097 of 1427

scale and to present a clean uniform
surface.
e) All irregularities, fins or risers shall be
ground off flush with the adjacent
surface. Castings with visible cracks,
blow holes or similar blemishes shall be
rejected if the imperfections are located
in bearing surfaces or cannot be
remedied to the approval of the
Engineer.
f) Imperfections which are not located in
bearing surfaces shall be cleaned out,
filled with weld metal of the
appropriate composition and ground
flush.
g) All surfaces of major components like
top plates, saddle plates, base plates,
rollers of the bearings shall be
machined all over for correct
alignment, interchangeability, proper
fining, etc.
2003.4. Tolerances
Tolerances for its individual components or

of the assembled bearings shall be as shown on the
drawings or subject to the approval of the Engineer.
Unless otherwise specified, the following

tolerances shall be maintained :
Diameter of Rollers, Knuckle Pins and
Page 1098 of 1427

Bores
Tolerances on diameter of rollers and all

convex surfaces conform to K7 of IS:919.
Tolerances on diameter of all concave

surfaces shall conform to D8 of IS:919. .
Height of Bearings
Tolerances on height of any component

casting shall not exceed +0.5mm. No minus
tolerance shall be allowed. The edges of ail ribs shall
be parallel throughout their length.
Base Plate
Tolerance on length and width of the base

plate shall not exceed +1.0 mm, tolerance on the
thickness of the plate shall not exceed +0.5 mm. No
minus tolerance shall be allowed. All rocking,
rolling and sliding surfaces shall have a machine
smooth finish to 20 micron maximum mean
deviation as per IS:3073.
Castings
No minus tolerance shall be allowed in the

thickness of any part of the castings. The edges of all
ribs shall be parallel throughout their length.
2003.5. Installation of Steel Bearings
Page 1099 of 1427

2003.5.1. General
a) Bearings shall be placed in the positions

as shown on the drawings with all
bearing surfaces in full contact and to the
tolerances as specified.
b) Roller and rocker bearings shall be
placed so that their axles of rotations arc
horizontal and normal to the direction of
movement of the members they support.
Upper and lower bearing plates shall
be set horizontal in both directions.
c) During installation the bearings shall
be pre-set with respect to the bearing
axis to account for the movement due
to the following :
i) Temperature variation between the

average temperature prevailing at the
time of installation and the mean
design temperature.
ii) Shrinkage, creep and elastic
shortening.
d) For bridges in gradient, the bearing

plates shall be placed in a horizontal
plane.
2003.5.2. Placing
(i) On supporting structures, pockets
Page 1100 of 1427

shall be provided to receive anchor
bolts; one side of the pocket shall project
beyond the bearing plate The pocket
shall be filled with mortar of mix 1:1
and the concrete bearing area also shall
be finished level by a thin and stiff
mortar pad of mix 1:1 (the thickness
not exceeding 12 mm) just before
placing of bearing assemblies or bottom
plate on the concrete scat.
(ii) In case of precast girder: a recess of 6
mm shall be provided on then underside
with a level finish for housing the
bearing plate A thin and stiff mortar pad
of mix 1:1 with thickness not
exceeding 3 mm shall be provided
over the top plate before lowering
the precast beam in position in order IP
ensure full and even pressure on the
plate surface.
(iii) It shall be ensured that while placing
the girder?, die bearings are in their
exact positions as indicated on the
approved drawing and not displaced
therefrom.
(iv) All concrete surfaces to be in contact
with the mortar shall be thoroughly
cleaned and kept saturated with water
for a period not less than 24 hours
before placing mortar and operations
are to be carried out when the surface
temperatures of the exposed bearings
Page 1101 of 1427

are the minimum practical.
(v) No mortar that is more than 30 minutes
old after completion of mixing, shall be
used.
(vi) After placing and finishing the mortar,
the bearing shall be checked for
position and shims or other temporary
supports removed and the mortar made
good. If the bearing has moved, it or the
plate shall be lifted, the mortar removed
and the whole procedure repeated.
(vii) Exposed laces of the mortar shall
be cured under damp Hessian for 7
days.
(viii) Placing of the bearing and mortar shall
only be carried out in the presence of
the Engineer.
2003.5.3. Checking, cleaning and

lubrication : Before erection, each bearing shall be
uncrated, disassembled and checked. Any damaged
parts shall be made good for approval.
All bearings with sliding surfaces shall be

cleaned and lightly lubricated with an approved
lubricant immediately before erection.
2003.5.4. Testing
i) The materials to be used in the bearings

shall conform to the specifications laid
down in clause 2003.1.
Page 1102 of 1427

ii) If required, a suitable number of
complete bearings as specified by an
accepting authority shall be tested to 1.25
times the design load. Recovery should
be 100 per cent Contact surfaces shall be
examined by illumination source for any
defects, cracks, etc. Segmental rollers
shall be tested for design movements.
iii) For large lots (consisting of 12 sets or
more), be submitted as detailed below:
(a) Unless otherwise agreed upon by
the Engineer and the manufacturer,
the latter shall furnish a complete
report on the process of quality
control. The Engineer may appoint
an authorised inspection agency for
inspection purpose on his behalf.
Such an inspection agency shall also
submit reports to the Engineer
regarding various tests performed on
the bearing or certify the
acceptance of the bearings.
(b) Test certificates of all raw materials
shall be submitted. If
manufacturer’s test certificates arc
not available for the raw materials,
the bearings manufacturer shall
perform the necessary confirmatory
tests as per relevant cedes of practice
and shall furnish the test results.
(c) A detailed quality control system
including stage by stage
Page 1103 of 1427

inspection, starting from raw
materials upto the finished bearing
shall be submitted by the bearing
manufacturer.
(d) The Engineer snail reserve the right to
witness such inspection at manu-
facturer’s works with or without
prior permission of the
manufacturer. For this, the bearing
manufacturer shall have in-plant
testing facilities as far as possible
and practicable.
(e) The bearing manufacturer shall
maintain a list of consumption of
raw material for a period of at least
previous one year.
(f) Test certificates of bearings
manufactured during preceding one
year shall be made available at the
manufacturer’s works.
(g) In case the lot size of similar bearings
exceeds 12 sets as per the direction
of the Engineer, one extra set of
bearings for each 24 sets of
bearings or pan thereof, shall be
manufactured and the cost of such
extra bearings shall be borne by the
user.
(h) The Engineer shall select the extra
bearing(s) at random and shall
perform various tests including
destructive testing on it at his
Page 1104 of 1427

discretion, either al the
manufacturer’s works or at any other
approved lest laboratory, notwith-
standing the test reports submitted.
(i) In case there is a major discrepancy
regarding material, the engineer shall
declare the whole lot of bearings as
unacceptable.
(j) In case minor defects in fabrication,
like- welding or machining, it
found in the test bearing before
destructive testing and if the ten
bearing it found to be acceptable
after destructive testing, the minor
defects in the test bearings shall not
be a bar to the acceptance of the
entire lot
(k) The opinion of the Engineer in cases
(i) and (j) above shall be binding on
the manufacturer.
2004. SPECIAL BEARINGS 2004.1.

Spherical Bearing
This bearing only takes care of vertical load

and horizontal force due to sliding friction. The
bearing will permit uniaxial translatory movement
along longitudinal axis of the bridge and rotation
along all axes.
The bearing shall consist of the following

parts : Bottom Plate
Page 1105 of 1427

A bottom plate with concave surface is
integrally cast on circular/ square plate. The bottom
plate is connected to the sub-structure by means of
tight fined anchor bolts, which arc embedded in
concrete. The material of bottom plate shall be cast
steel.
Pure unfilled quality dimpled PTFE o!

specified thickness shall be provided on lop of
concave surface of bottom plate in order to allow
smooth rotation.
Saddle Plate
A saddle plate with

square/circular/rectangular lop and convex surface at
bottom shall be placed in the concave surface of
bottom plate. The radius of curvature of the convex
bottom of the saddle plate shall be slightly less than
that of the concave top surface of the bottom plate to
ensure sufficient contact over a small area. Rotation
along all axes shall be permitted along the contact
surface of the saddle plate and the bottom plate. Pure
unfilled quality dimpled PTFE sheet shall be
recessed to specified depth of recess over the top of
saddle plate. Suitable elastomeric seal shall be
provided on the saddle plate to prevent ingress of
dirt and moisture. The material of saddle plate shall
be cast steel.
Top Plate
Page 1106 of 1427

The top plate shall have stainless steel plate
welded to its bottom which shall slide over PTFE.
The assembly shall be connected to the
superstructure by tight fitted anchor bolts.
Translatory movements along longitudinal axis of
bridge shall be accommodated at the FIFE/ Stainless
steel sliding surface. The material of top plate shall
be cast steel.
Guide Plate
Guide Plates shall be welded to saddle plate

so as to permit only longitudinal movement. The
material of guide plates should be cast steel.
2004.2. Pin Bearing
Pin bearing shall ensure fixity by arresting

translatory movement. The pin bearing shall not take
any vertical load. It will take care of the longitudinal
horizontal force of the entire superstructure unit as
well as transverse horizontal force developed at the
fixed end.
A pin bearing shall consist of a short height

structural built-up column embedded in pier cap and
the protruding length inside soffit of deck shall have
rocker plates on all four sides, which permit rotation.
Pin bearing shall resist horizontal force from

any direction and will permit rotation but will not
Page 1107 of 1427

bear any vertical load. The material of pin bearing
including rocker plates shall be high tensile steel
2004.3. In general the sliding spherical and

pin bearing shall conform to BS:5400, Parts 9.1 and
9.2 and all relevant clauses of this specification.
Bearings shall be guaranteed for design loads and
movements. The term bearing shall include the
entire assembly covering all the accessories
required for operation, erection and dismantling for
replacement All bearings shall be of replaceable
type. These bearings should be based on their
design to the specifications
mentioned/international specifications. The
manufacturer should get their design approved from
appropriate authority and the manufacturer
should be associated with installation of bearings.
2004.-4. Materials
All materials, particularly the following, shall

be original, unused or non-re-cycled conforming to
relevant specifications :
 Cast Steel; Mild Steel, Stainless Steel
shall conform to Clause 2003.1.
 Copolymer Poly Tetra Fluora
Ethylene (PTFE) unfilled quality shall
have required properties as per
BS:S400 and thickness shall be as
specified.
 Anchor Bolts shall be as per relevant
Page 1108 of 1427

IS specifications.
2004.5. Seating of Pin Bearing
i) Backing plate with studs welded on

the face opposite to the seating of
manufacture shall be delivered by the
manufacturer.
ii) This backing plate shall be accurately
positioned on the reinforcement grid of
the pedestal and levelled.
iii) Studs shall be tack welded / tied to
the reinforcement to keep the backing
plate in proper location during casting.
iv) Depth of embedment of the hacking
plate in the concrete shall be as per
relevant drawing.
v) The round base of the pot (bottom) of
the pin bearing assembly shall be
connected to the backing plates by anchor
screws after concreting of pier
cap/pedestal.
vi) In order to ensure successful transfer
of large horizontal forces to be resisted
by the Pin bearing, great care shall be
taken in detailing the reinforcement in the
sub-structure and the super-structure
adjacent to the studs in the backing plate.
2004.6. Acceptance Test on Spherical

Bearings
Page 1109 of 1427

1. All bearings shall be checked for overall
dimensions
2. All bearings shall be load tested to 1.25
limes design vertical load
3. A pair of bearings selected at random
shall undergo testing in order to
determine coefficient of friction which
shall be less than 0.05.
4. Two bearings selected at random shall
be tested for permissible rotation.
2904.7. Acceptance Test on Pin Bearings
1. All bearings shall be checked for

overall dimensions.
2. All bearings shall be load tested (if
required, for design horizontal load only)
2005. ELASTQMERIC BEARINGS
The term “bearing” in this case refers to an

elastomeric bearing consisting of one or more
internal layers of elastomer bonded to internal steel
laminates by the process of vulcanisation. The
bearing shall cater for translation and/or rotation of
the superstructure by elastic deformation.
2005.1. Raw Material
Chloroprene (CR) only shall be used in the

manufacture of bearing.
Page 1110 of 1427

Grades of raw elastomer of proven use in
elastomeric bearings, with low crystallization rates
and adequate shelf life (e.g. Neoprene WRT,
Bayprene 110, Skyprene B-5 and Denka S-40V)
shall be used.
No reclaimed rubber or vulcanized wastes or

natural rubber shall be used.
The raw elastomer content of the compound

shall not be lower than 60 per cent by its weight The
ash content shall not exceed 5 per cent, (as per tests
conducted in accordance with ASTM D-297, sub-
section 10).
EPDM and other similar candidate

elastomers for bridge bearing use shall not be
permitted.
Properties
The elastomer shall comform to the

properties specified in Table 2000.1
TABLE 2000-1. PROPERTIES OF

ELASTOMER
Property Unit Test Method, IS
specification
reference
1. Physical Properties
1.1. Hardness IRHD 1S:3400 ‘
(Part II)
Page 1111 of 1427

1.2. Minimum Tensile MPa 1S:3400
Strength (Pan I)
1.3. Minimum Elongation Per cent 1S:3400
at break (Part I)
2. Maximum Compression
Set Per cent IS 3400
(Pan X)
duration tempera
(h) (deg C
CR +0 to 100 ± 1
24.2
3. Accelerated Ageing
IS:3400
(Part IV)
duration temperat
(h) (deg C
CR 70 100±1
3.1 Max change in
Hardness IRHD
3.1 Max change in Per cent
Tensile Strength
3.3. Max change m
Elongation Per cent
Shear modulus of the elastomer bearing shall

neither be less than 0.80 MPa nor greater than 1.20
MPa.
The adhesion strength of elastomer to steel
plates determined according to 1S:3400 (Pan XIV)
method A shall not be less than 7 kN/m.
For elastomeric bearings (CR) used in
adverse climatic conditions the following ozone
Page 1112 of 1427

resistance test shall be satisfied :
The ozone resistance of elastomer shall be

proved satisfactory when assessed by test according
to IS:3400 (Part XX). The strain, temperature,
duration and ozone concentration of the test shall be
20 per cent, 40 + 1 degree Celsius, 96 h and 50 pphm
by volume respectively.
No cracking detected by visual observation at

the end of the test shall be considered satisfactory.
No specific tests for assessment of low temperature
resistance’ may be deemed necessary.
NOTE : For use of elastomer in extreme cold

climates, the Engineer may specify special grade of
low temperature resistant elastomer in conformity
with operating ambient temperature conditions. The
specifications of such special grade elastomer
including the tests for low temperature resistance
shall be mutually agreed to by the Engineer and the
producer supplier and are outside the purview of
Laminates of mild steel conforming to IS:226

shall only be permitted to be used. Use of any other
material like fibre glass or similar fabric as laminates
shall not be permitted.
The manufacturers of elastomeric bearings

shall satisfy the Engineer that they have in-house
facilities for testing the elastomer for carrying out
Page 1113 of 1427

the following tests in accordance with the. relevant
provisions of ASTM D-297.
a) Identification of polymers : to
confi
rm
the
usag
e of
Chlo
ropre
ne
(App
endi
x X-
2)
b) Ash content test : to
deter
mine
the
perce
ntage
(sub-
secti
on
34)
c) Specific gravity test : (sub-
secti
on
15)
d) Polymer content test : (sub-
secti
on
Page 1114 of 1427

10)
The Engineer shall invariably get the test (a)

performed within his presence or in the presence of
his authorised representative to satisfy the
requirement In case of any disputes regarding
interpretation of results the Engineer may carry out
test as per ASTM S-3452-78 (Chromatography test)
at the manufacturer’s cost in a recognised test house.
The elastomer specimen to conduct the test

shall be obtained from the bearings selected at
random for destructive test, Remaining part of the
test bearing shall be preserved by the Engineer for
any test to be done in future, if required.
2005.2. Fabrication
Bearing with steel laminates shall be cast as a

single unit in a mould and vulcanised under heat and
pressure.
Casting of elements in separate units and

subsequent bonding shall not be permitted, nor shall
cutting from large size cast be permitted.
Bearings of similar size to be used in

particular bridge project shall be produced by
identical process and in one lot as far as practicable.
Phased production may only be resorted to when the
total number of bearings is large enough.
Page 1115 of 1427

The moulds used shall have standard surface
finish adequate to produce bearings free from ‘any
surface blemishes.
Steel plates for laminates shall be sand

blasted, clean of all mill scales and shall be free form
all contaminants prior to bonding by vulcanisation.
Rusted plates with pitting shall not be used. All
edges of plates shall be rounded.
Spacers used in mould to ensure cover and

location of laminates shall be of maximum size and
number practicable. Any hole at surface or in edge
cover shall be filled in subsequently.
Care shall be taken to ensure uniform

vulcanising conditions and homogeneity of
elastomer through the surface and body of bearings.
The bearings shall be fabricated with the

tolerances specified in Table 2000-
TABLE 2000-2 TOLERANCES
ITEMS TOLERANCES-
1. Overall plan -0, + 6 mm

dimensions -0, + 5 mm
2. Total bearing
thickness
3. Parallelism 1 in 200
a) Of top surface of
Page 1116 of 1427

bearing with 1 in 100
respect to the ± 20 per cent (max. of 2
bottom surface as mm)
datum
b) Of one side -0, + 1 mm
surface with -3mm, +0
respect to the ±10 per cent
other as datum
4a. Thickness of 1 in 100
individual
internal layer of
elastomer
b) Thickness of
individual outer layer
5a. Plan dimensions
of laminates
b) Thickness of
laminate:
c) Parallelism of
laminate with
respect 10
bearing base as
datum
The vulcanising equipment/press shall be

such that between the plattens of press the pressure
and temperature are uniform and capable of being
maintained at constant values as required for
effecting a uniform vulcanistion of the bearing.
The moulding dies utilised for manufacturing
Page 1117 of 1427

the bearings shall be so set inside the platten of the
press so that the pressure developed during
vulcanisation of the product is evenly distributed and
the thickness maintained at all places are within
acceptable tolerance limits taking into consideration
the shrinkage allowance of vulcanizate.
The raw compound which has been

introduced inside the metal dies for vulcanisation
shall be accurately weighed each time and it must be
ensured that sufficient quantity has been put inside
the die for proper flow of material at every place so
that a homogeneous and compact bearing is
produced without any sign of sponginess or
deficiency of material at any place.
Before any vulcanizate of any batch of

production is used for producing vulcanised
bearings, test pieces in the form of standard slab and
buttons shall be prepared in accordance with
prescribed standards and salient properties tested and
recorded regularly against each batch of production
to monitor the quality of the products.
2005.3. Acceptance Specification
The manufacturer shall have all the test

facilities required for the process and acceptance
control tests installed at his plant 10 the complete
satisfaction of the Engineer. The test facilities and
their operation shall be open to inspection by the
Engineer on demand.
Page 1118 of 1427

All acceptance and process control tests shall
be conducted at the manufacturer’s plant. Cost of all
materials, equipment and labour shall be borne by
the manufacturer unless otherwise specified or
specially agreed to between the manufacturer and
Engineer.
Acceptance testing shall be commenced with

the prior submittal of testing programme by the
manufacturer to the Engineer and after obtaining his
approval.
Any acceptance testing delayed beyond 180

days of production shall require special approval of
the Engineer and modified acceptance specification,
if deemed necessary by him.
All acceptance testing shall be conducted by

the Inspector with aid of the personnel having
adequate expertise and experience in rubber
testing provided by the manufacturer,

working under the supervision of the Inspector
and to his complete satisfaction.
Lot by lot inspection and acceptance shall be

made.
2005.3.1. Acceptance lot : A lot under

acceptance shall comprise all bearings, including the
pair of extra test bearings where applicable of equal
Page 1119 of 1427

or near equal size produced under identical
conditions of manufacture to be supplied for a
particular project.
The size and composition of acceptance lot

shall be got approved by the Engineer.
For the purpose of grading levels of
acceptance, testing lots shall be classified as follows
:
i) A lot size of 24 or larger number of

bearings shall be defined as a large lot
ii) A lot size of less than 24 bearings shall
be defined as a small lot
When the number of bearings of equal or

near equal size for a single bridge project is large
and phased production and acceptance is permitted,
the number of bearings supplied in any single phase
of supply shall comprise a lot under acceptance.
When such phased supply is made, each such lot
shall be considered as a large lot for the purpose of
acceptance testing.
2005.3.2. Levels of acceptance inspection :

The level of acceptance testing shall generally be
graded into the following two levels depending on
lot size :
Level 1 acceptance testing Level 2

acceptance testing
Page 1120 of 1427

Acceptance testing Level 1 is a higher level
inspection and shall be applicable to large lots only,
unless otherwise specified. This shall involve
manufacture of two extra bearings for each lot to be
used as test bearing and eventually’ consumed in
destructive testing.
Acceptance testing Level 2 shall be

applicable to small lots only, (i.e. less than 24 lots)
for which one extra bearing shall be manufactured.
Out of the lot one bearing shall be selected at
random for carrying out material tests. This bearing
shall be excluded from the lot accepted.
Acceptance inspection level 1 may be

specified at the sole discretion of the engineer taking
into account the special importance of bridge project
for small lots also under the purview of special
acceptance inspection. The cost of extra bearings, in
such cases shall be borne by the user, while the cost
of all other materials, equipment and testing shall be
borne by the manufacturer.
2005.3.3. Testing : Acceptance testing shall

comprise general inspection, test on specially
moulded test pieces and test on complete bearings or
sections for measurement of various quality
characteristics detailed below :
2005.3.3.1. Acceptance testing level 1

General Inspection
Page 1121 of 1427

i) All bearings of the lot shall be visually
inspected for any defects in surface
finish, shape or any other discernible
superficial defects.
ii) All bearings of the lot shall be checked
for tolerances specified in Table 2000-
iii) All bearings of the lot shall be subjected
to axial load to correspond to am (i.e.
average compressive stress) = 15 MPa
applied in steps and held constant while
visual examination is made to check
for discernible defects like :
(a) Misalignment of reinforcing plates
(b) Poor bond at laminate/steel Interface
(c) Variation in thickness of elastomer
layers
(d) Any surface defects
(e) Low stiffness
Deflection under loads between m=5 MPa

and m-15 MPa shall be measured and recorded for
all bearings with sufficient accuracy (± 5 per cent),
Variation in stiffness of any individual bearing from
the mean of the measured values for all such
bearings of the lot shall not be larger than 20 per
cent (of the mean value).
Tests on specially moulded test pieces
i) Test pieces shall be moulded by the

manufacturer with identical compound
and under identical vulcanising
Page 1122 of 1427

conditions as used in the manufacture
of the bearings of the acceptance, lot.
The process shall be open to inspection
by the Engineer
ii) Test pieces offered for inspection shall
be identified by suitable markings and
duly certified by the manufacturer.
iii) The quality characteristics to be
tested are listed below. The
specification references in parenthesis
shall define the corresponding
specification for lest piece, test
method and criterion for acceptance.
Composition (see Note 1 below)

Hardness (Table 2000-1 ,1.1)
Tensile strength (Table 2000-1 , 1.2)

Elongation at Break (Table 2000-1 , 1.3)
Compression Set (Table 2000-1 , 2)
Accelerated Ageing (Table 2000-1 , 3)
Adhesion Strength (Clause 2005.1)
Ozone Resistance (see Note 2 below)
Note 1.
For acceptance testing the properties

enumerated in Clause 2005.1 and specific gravity of
elastomer of test pieces from test bearing shall be
compared with those for corresponding specially
moulded test pieces furnished by the manufacturer.
The following variations shall be deemed maximum
Page 1123 of 1427

acceptable :
Specific Gravity ± 0.2

Ash-Content ± 0.5 per cent
Hardness (Table 2000-1 ,1.1)
Tensile strength (Table 2000-1 , 1.2)
Elongation at Break (Table 2000-1 , 1.3)
Compression Set (Table 2000-1 . 2)
Accelerated Ageing (Table 2000-1 , 3)
Adhesion Strength (Clause 2005.1)
Note 2.
Ozone resistance test can be waived by the

Engineer for bearings of CR when satisfactory
results of ozone resistance tests on similar grade of
elastomer may be available from process control
records or development test data furnished by the
manufacturer.
Where such process control data are not

available or the frequency of testing not deemed
adequate, ozone resistance test shall be mandatory
for acceptance of bearings of CR.
However, such tests may not be insisted for

bearings not located under adverse conditions of
exposure and where the test on accelerated ageing
could be considered as adequate.
Process and acceptance control tests for

ozone resistance by an independent testing agency
Page 1124 of 1427

shall be acceptable.
Tests on Complete Bearings or Sections

i) Two bearings shall be selected at random
from the lot as test bearings. These
bearings shall be excluded from the
lot accepted.
ii) The following tests shall be conducted on
test bearings :
Test for determination of shear modulus

Test for determination of elastic modulus
Test for determination of shear modulus
(short term loading)
Test for determination of adhesion
strength
Test for determination of ultimate
compressive strength
The test specifications and acceptance

criteria shall conform to those given in Appendix 2
of IRC:83 (Part II).
2005.3.3.2. Acceptance testing level 2
General Inspection. This shall conform to

the provision in Clause 2005.3.3.1 in all respects.
Test on specially moulded test pieces. This

shall conform to the provisions in Clause 2005.3.3.1
in all respects.
Page 1125 of 1427

Test on complete bearings. Test for
determination of shear modulus shall be conducted
using two bearings of the lot selected at random and
conforming to relevant provisions of Clause
2005.3.3.1. These bearings shall however be part of
the lot accepted. The remaining tests stipulated in
aforesaid clause shall be carried out on all bearings
selected at random which shall be excluded from the
lot accepted.
2005.3.4. Special acceptance inspection

: Special acceptance inspection may comprise the
following :
i) Acceptance testing by an
independent external agency with
separate or supplemental test facilities
provided by it.
ii) Acceptance testing on test pieces
prepared from the surface or body of
the test bearings instead of specially
moulded lest pieces.
iii) Acceptance tests not covered by these
specifications but according to the speci-
fications laid down by the Engineer.
Special acceptance inspection may be

specified under the following conditions :
a) Special contract agreement

b) Unsatisfactory evidence of process or
acceptance control
Page 1126 of 1427

2005.3.5. Inspection certificate : A lot
under inspection shall be accepted by the Inspector
and so certified, when no defect is found with
respect to any of the quality characteristics tested
on samples drawn from the lot according to
specifications laid down in Clause 2005.3.3 covering
general inspection tests on specially moulded test
pieces and on complete bearings.
In case of any bearing with defect, the lot

shall be rejected by the Inspector and so certified.
In case any bearing is found to be defective

with respect to any quality characteristic, discerned
by general inspection tests specified in Clauses
2005.3.3.1 and 2005.3.3.2, tests on specially
moulded test pieces and complete bearings as
applicable according to Clauses 2005.3.3.1 and
2005.3.3.2 shall nevertheless be completed. If the
said lot, rejected by general inspection, satisfies the
acceptance criteria in respect of these other tests, the
lot and individual bearings found defective shall be
clearly identified in the inspection certificate.
The manufacturer shall obtain .from the

inspector, authorised by the Engineer, immediately
on completion of his inspection, an inspection
certificate which shall include the details of a lot or
lots accepted/rejected by him and records of all test
measurements.
Page 1127 of 1427

2005.3.6. Quality control certificate : The
manufacturer shall certify for each lot of bearing
under acceptance:
That an adequate system of continuous

quality control was operated in his plant.
Thai the. entire process remained in control
during die production of the lot of bearings under
acceptance as verified from the quality control
records/charts which shall be open to inspection of
Engineer/ Inspector on demand.
A certified copy of results of process in

control testing done on samples of elastomer used in
the production of the lot shall be appended and shall
include at least the following information :
Composition of compound - raw elastomer

and ash content, the grade of raw elastomer used
(including name, source, age on shelf), test results of
hardness, tensile strength, elongation at break,
compression set, accelerated ageing, etc.
A higher level certification of the process

quality control shall be called for at the sole
discretion of the Engineer in special cases e.g. where
adequate inspection of bearings similar to those
comprising the lot under inspection produced in the
same plant is not available with the Engineer or in
case of any evidence of process or acceptance
control -being deemed unsatisfactory. The higher
level certification shall comprise submittal of a
Page 1128 of 1427

complete quality control report as given in Appendix
3 of IRC:83 (Part II) supplementing the quality
control certificate.
2005.3.7 Acceptance : The manufacturer

shall furnish the following to Engineer for the
acceptance judgment :
1. Quality control certificate as laid down

in Clause 2005.3.6.
2. Inspection certificate as laid down in
Clause 2005.3.5.
The manufacturer shall furnish any

supplementary information on the system of quality
control and/or process and acceptance control testing
as may be deemed necessary by the Engineer.
In case of any evidence of process or

acceptance control testing being deemed
unsatisfactory by him. Engineer at his sole discretion
may call for a special acceptance of the lot according
to specifications laid down by him, without any
prejudice to his right to reject the lot. The entire cost
of such supplementary inspection shall be borne by
the manufacturer.
The Engineer shall be the sole authority for

acceptance of a lot on scrutiny of the certificates
along with any supplementary evidence and
complete satisfaction therewith.
Page 1129 of 1427

In case of rejection of a lot, the Engineer
shall reserve the right to call for special acceptance
inspection for the succeeding lots offered for
inspection, according to the specifications laid down
by him. The entire cost of such tightened inspection
shall be borne by the manufacturer.
2005.4. Certification and Marking
Bearings shall be transported to bridge site

after final acceptance by Engineer and shall be
accompanied by an authenticated copy of the
certificate to that effect.
An information card giving the following

details for the bearings, duly certified by the
manufacturer shall also be appended :
Name of manufacturer
Date of manufacture
Elastomer grade used
Bearing dimensions
Production batch no.
Acceptance lot no.
Date of testing
Specific bridge location, if any

Explanation of markings used on the bearing
All bearings shall have suitable index

markings identifying the information. The markings
shall be made in indelible ink or flexible paint and if
Page 1130 of 1427

practicable should be visible after installation. The
top of the bearing and direction of installation shall
be indicated.
2005.5. Storage and Handling
Each elastomeric bearing shall be clearly

labeled or marked. The bearing shall be wrapped in a
cover. They shall be packed in timber crates with
suitable arrangement to prevent movement and to
protect comers and edges.
Care shall be taken to avoid mechanical

damage, contamination with oil, grease and dirt,
undue exposure to sunlight and weather to the
bearings during transport and handling prior to and
during installation.
2005.6. Installation
Installation of multiple bearings one behind

the other on a single line of support shall be of
identical dimensions.
Bearings must be placed between true

horizontal surfaces (maximum tolerance 0.2 per cent
perpendicular to the load) and at true plan position of
their control lines marked on receiving surfaces
(maximum tolerance ± 3 mm).
Concrete surfaces shall be free from local

irregularities (maximum tolerance ± 1 mm in
Page 1131 of 1427

height).
Design shall be checked for the actual

inclination in seating if larger inaccuracies than
those specified are permitted.
For cast-in-place concrete construction of

superstructure, where bearings are installed prior to
its concreting, the forms around the bearings shall be
soft enough for easy removal. Forms shall also fit the
bearings snugly and prevent any leakage of mortar
grout. Any mortar contaminating the bearings during
concreting shall be completely removed before
setting.
For precast concrete or steel superstructure

elements, fixing of bearing to them may be done by
application of epoxy resin adhesive to interface, after
specified surface preparation. The specifications for
adhesive material, workmanship and control shall be
approved by the Engineer. Care shall be taken to
guard against faulty application and consequent
behaviour of the adhesive layer as a lubricant. The
bonding by the adhesive shall be deemed effective
only as a. device for installation and shall not be
deemed to secure bearings against displacement for
the purpose of design.
As a measure of ample safety against

accidental displacement, the bearings shall be placed
in a recess as shown in Fig. 9 of IRC:83 (Pan II).
Page 1132 of 1427

2005.7. Seating of Elastomeric Bearings on
a Non-Horizontal Plane
Installation of elastomeric bearings on a Non-

Horizontal Plane shall be as follows:
(i) Elastomeric bearings shall be delivered
with MS backing plate fastened to the
bearing from the manufacturer.
(ii) Template of 6 mm M.S. plate and of size
same as bearing holding base plate with
matching holes for the anchor screws
shall be used. Anchors shall be fitted to
the templates with the anchor screws but
with MS washers in place of elastomer
washers. The above template assembly
shall be fitted in the formwork at its
proper location and in a vertical plane.
(iii) After casting of the pedestal and
removal of the formwork, the template is
to be removed.
A. Installation with face plate and
without template in-situ casting
(i) The sub-assembly of elastomeric bearing

with the MS backing plate snail be fitted
to the embedded anchors with anchor
screws and elastomeric washers
replacing the steel washer.
(ii) A clearance is required between the
stainless steel face of the elastomeric
bearing and that of the vertical face of
the face plate with stainless steel top
Page 1133 of 1427

installed on the projection below the
soffit. This shall be achieved by
inserting removable steel sheeting of
thickness as per the drawing, during
preparation of the form work before
casting of the superstructure.
(iii) The face plate with stainless steel top
and pack plate shall be assembled with
the anchors with elastomeric washers
and anchor screws. The assembly shall
be fitted in the formwork at its proper
location and in a vertical plane. The
removable steel shims shall be removed
at an appropriate time after the casting of
the super-structure.
B. Installation with face plate and with

template in-situ casting
i) Template of 6 mm MS plate and of size

same as face plate with stainless steel lop
and matching holes for the anchor screws
shall be used. Anchors shall be fitted to
the templates with the anchor screws but
with MS washers in place of elastomer
washers. Separate screws may be used in
case of inconvenience of in the length of
original anchor screws. The above
template assembly shall be fitted in the
formwork for the super-structure at its
proper location and in a vertical plane.
ii) After removal of the superstructure
Page 1134 of 1427

formwork, the template shall be removed.
iii) The face plate with the required thickness
of pack plate shall be loosely fined to the
anchors embedded in the projection
below the superstructure, with elastomer
washers and anchor screws.
iv) The sub-assembly of elastomeric bearing
with the MS backing plate shall be fitted
to the embedded anchors in the pedestal
with anchor screws and elastomeric
washers replacing the steel washer this
time.
v) The required clearance between the
stainless steel face of the elastomeric
bearing and that of the vertical face plate
installed on the projection below the
soffit shall be checked. After adjustment
of the required working clearance the
small gap between the vertical face of the
projection below the soffit and the back
of the face plate (with pack plates, if any)
shall be grouted with epoxy grout.
2006. POT BEARINGS
2006.1. General
2006.1.1. Pot type bearings shall consist of a

metal piston supported by a disc or unreinforced
elastomer confined within a metal cylinder to take
care of rotation. Horizontal movement, if required,
shall with a system of sealing rings be provided by
Page 1135 of 1427

sliding surfaces of PTFE pads sliding against
stainless steel mating surfaces. The pot bearings
shall consist of cast steel assemblies or fabricated
structural steel assemblies.
2006.1.2. Provisions of IRC-83 (Part I)

shall be applicable for all metallic elements.
Provisions of IRC:83 (Part II) shall be applicable for
all elastomer elements. When any items are not
covered by IRC:83 (Parts I and II), the same shall be
as per guidelines given hereunder and BS:5400
(Sections 9.1 and 9.2), except that no natural rubber
shall be permitted. If there is any conflict between
BS on the one hand and IRC on the other, the
provisions of ERC will be guiding.
2006.13. Combination bearings using any

judicious combination and sliding element shall be
permitted. As for example :
Name Rotation Sliding Element Generally for

Dement
Pot Pot None Vertical Load
Elastomer Elastomer None* Horizontal Bu
Pot PTFE Pot PTFE-SS** Vertical Load
Horizontal Lo
Spherical Spherical PTFE-SS** Vertical Loa
Knuckle PTFE Knuckle Load
Elastomer Elastomer PTFE-SS** Transverse Gu
PTFE
Elastomer SS** Elastomer SS-SS** Transverse Gu
Page 1136 of 1427

* Elastomer shall permit movement by
shear ** Stainless Steel
For special and innovative bridges, new

combinations beyond what is shown may be
required. The same may be used after approval by
the Engineer.
2006.2. Fabrication
i) The surface mating with the PTFE in the

sliding pair shall be corrosion resistant
stainless steel. Normally, the stainless
steel shall form the upper component.
The stainless steel shall overlap the PTFE
after full movement on all sides. If
stainless steel sheet is used, it should be
bonded by continuous welding along the
edges. Adhesive or any other bonding can
be approved by the Engineer. The surface
shall be prepared by thorough cleaning to
remove grease, dust or any other foreign
substance.
ii) PTFE modular sheets of the sliding pair
shall be located by confinement assisted
by bonding. Confined PTFE shall be
recessed into the metal backing plate. The
shoulders of the recess shall be sharp and
square to restrict the flow of PTFE.
iii) The thickness of the PTFE shall not be
less than 4.5 mm with projection above
Page 1137 of 1427

the recess not exceeding 2.0 mm. When
the piston is subjected to tilting, the seal
must slide along the wall and alter its
shape according to the angle of tilt. At the
same time, it must be sufficiently rigid to
bridge the gap between the piston and the
wall of the pot. However, the percentage
of plan area of the lubrication cavities to
the gross area shall not exceed 25 per
cent. The depth of the cavity shall not
exceed 2.0 mm.
iv) The diameter to thickness ratio of the
confined elastomer shall not exceed 15.
The surface of the confined elastomer
shall be smooth.
v) A seal shall be provided to prevent
extrusion of the confined elastomer
between the piston and the pot wall. The
seal should slay functional under the
loads and relations acting on it.
Additional seal shall be provided to
prevent entry of dust into the pot Sealing
rings for .pot bearings shall be fabricated
from stainless steel. When the piston is
subjected to tilting, the sea! must slide
along the wall and alter its shape
according 10 the angle of till. At the same
time, it must’ be sufficiently rigid to
bridge the gap between the piston and the
wall of the pot
vi) The hardness of the piston and pot wall at
their contact region shall be minimum
Page 1138 of 1427

350 BHN to reduce wear. The surface
finish of the pot base in contact with the
confined elastomer shall be very smooth.
vii) All bearings shall be installed with
anchor and anchor screws or some
similar device such that while replacing,
the bearings can be removed with
minimum lifting of the superstructure.
viii) The external surfaces of the assemblies
shall be completely cleaned by sand
blasting. After sand blasting, dust shall
be removed from the surface using clean
and dry compressed air or a clean brush
after which suitable coating shall be
applied.
ix) Pot bearings including all parts as shown
on the drawings shall be fully shop
assembled at the manufacturer’: works
to ensure proper fitting of ail pans.
2006.3. Materials
a) Steel
i) Structural steel shall conform to

1S:226 and IS:2062, as applicable.
ii) Cast steel shall conform to Gr 280-
520W of IS: 1030. 0.3 to 0.5 per
cent copper may be added to
increase the corrosion resistance
properties.
iii) Stainless steel shall conform to
Page 1139 of 1427

AISI:304 or XO4Crl8NilO of
15:6911 for ordinary applications.
For applications with
adverse/corrosive environment, the
stainless steel shall conform to
AISI:316L or O2Crl7Nil2Mo2 of
IS:6911.
b) PTFE
PTFE (poly tetra fluoro ethylene) shall

be of unfilled pure virgin quality. It
shall be free sintered. The mechanical
properties of unfilled PTFE shall
comply with Grade A of BS:3784.
c) Elastomer
The confined elastomer inside pot

will have the following properties
i) Hardness IRHD IS:3400

(Part II) 50 + 5
ii) Min tensile MPa strength
IS:3400 (Part I) 15.5
iii) Min elongation at break,) shall be
as per Table 2000-1
Max compression set and )
“Properties of Elastomer”
Accelerated ageing )
Page 1140 of 1427

For other details, refer to Clause
2005.1. 2006.4. Workmanship
2006.4.1. Welding
All welding shall conform to 15:9595 with

electrodes of suitable grade as per IS:814. Preheating
and post weld stress relieving shall be done as per
IS:9595.
2006.4.2. Cast steel assemblies : Cast steel
for pot bearing assemblies shall conform to
requirements of relevant IS. Castings shall be true to
the forms and dimensions shown on the
drawings, and shall be free from pouring faults,
sponginess, cracks, blow holes and other defects
affecting their appearance or their strength. Warped
or distorted castings shall not be accepted. Exposed
surfaces shall be smooth and dense.
All irregularities, fins or risers shall be

ground off flush with the adjacent surface. Castings
with visible cracks, blow holes, or similar blemishes
shall be rejected if the imperfections are located on
bearing surfaces or cannot be remedied to the
Imperfections which are not located on

bearing surfaces shall be cleaned out, filled with
weld metal of the appropriate composition and
ground flush with adjacent surfaces.
2006.4.3. Structural steel assemblies :
Page 1141 of 1427

Defects arising from the fabrication of the steel
shall be inspected by the Engineer, who will decide
whether the materials may be repaired by .the
Contractor or will be rejected. The cost of repairs or
replacement shall be borne by the Contractor.
All steel whether fabricated or not, shall be

stored above the ground on platforms, skids, or other
supports, and adequately protected against corrosion.
Excessively rusted, bent or damaged steel shall be
rejected.
All plates shall be flat and rolled bars and

shapes straight before marking out or being worked .
Straightening shall be done by methods which shall
not damage the material. Sharp kinks and bends shall
be the cause for rejection.
Steel may be flame cut to shape and length so

that a regular surface, free from excessive gouges
and striations is obtained. Flame cutting by hand
shall be done only with the approval of the Engineer.
Exposed corners shall be machined or

ground.
2006.4.4. Tolerances
i) Plan dimensions .0 10 ±5 mm
ii) Overall height -0 to ±3 mm

iii) Height of elastomer ± 5 per cent
Page 1142 of 1427

iv) Height of any steel
component -0 to +1 mm
a) Machined Class 2 of IS:4897
b) Unmachined
v) Stainless steel sliding
surface 0.0004L, where L =
a) Flatness length in direction of
measurement
b) Surface Finish Ra <= 0.25 pm as per
IS:3073
2006.4.5. Painting
All non working surfaces shall be coated

with two coats of epoxy primer and one or more coat
each of epoxy intermediate and finish, total thickness
< 0.1 SO pm or any other painting scheme as
Silicon grease shall be applied at the

PTFB/SS interface after testing. Anchor sleeves shall
be cement coated at the manufacturer’s works.
2006.5. Test
2006.5.1. Raw materials : Necessary test

certificates for all raw materials as in Clause 2006.3
above shall be furnished by manufacturers.
Reference may also be made to Clause 2005.1 for
tests on elastomers.
Page 1143 of 1427

2006.5.2. Test on casting : Tests specified in
IS: 1030 shall be performed. Castings shall be
ultrasonically tested and certificates submitted.
Quality level of castings shall be level 3 as per
IS:9565.
2006.5.3. Test on welding : All welding

shall be tested by Dye Penetration method. But
welding shall be tested by Ultrasonic method.
Soundness of welding shall be certified by the
manufacturer.
2006.5.4. Acceptance test on bearing

i) All bearings shall be checked for overall
dimensions.
ii) All bearings shall be load tested to 1.1
times maximum design capacity
including seismic force. Bearing tested at
higher loads cannot be used.
iii) A pair of bearings selected at random will
undergo testing in order to determine the
coefficient of friction “µ”. The
coefficient of friction shall be < = 0.05
at the design load.
iv) Two bearings selected at random
shall be tested for permissible rotation.
2006.6. Installation of POT-cum-PTFE

Bearings 2006.6.1. General
i) Care shall be taken during installation of

the bearings to permit their correct
Page 1144 of 1427

functioning in accordance with the design
scheme.
ii) To prevent contamination, dismantling of
the bearings at site shall not be done.
iii) The load shall be transferred onto the
bearings only when the bedding material
has developed sufficient strength. The
props for the formwork shall only be
removed after lapse of appropriate time.
In special cases, this can be ensured by
suitable devices like jacks, etc.
iv) Temporary clamps and shims (introduced
to maintain working clearance) shall be
removed at an appropriate time, before
the bearing is required to permit
movement
v) Permitted installation tolerance of the
bearing from- plane of sliding shall be
maintained.
vi) Cement based non-shrink grout with air
releasing additive end epoxy based grout,
whichever is specified shall be first tried
at the she. For the proprietary grout
mixes, appropriate instructions from the
manufacturer shall be followed specially
with regard to the following :
(a) Preparation -> concrete cleaning,
roughening, pre-soaking, etc.
(b) Forms->sturdiness, leak proofing,
shape, header funnel vents, etc.
(c) Bearing Base -> cleaning, etc.
(d) Placement -> mixing, consistency,
Page 1145 of 1427

time period, finishing, etc.
(e) Protection -> curing, ambient
temperature, etc.
2006.6.2. In-situ casting of superstructure
i) Formwork around the bearing shall be

carefully sealed to prevent leakage.
ii) Sliding plates shall be full) supported and
care taken to prevent tilting, displacement
or distortion of the bearings under the
weight of wet concrete.
iii) Bearings shall be protected during
concreting operation. Any mortar
contaminating the bearing shall be
completely removed before it sets.
2006.6.3. Seating of bearing
A. Using Template
i) Template with required rigidity and
matching holes corresponding to the
base of the bearing shall be used.
ii) All the anchors shall be fitted to the
lower face of the template using the
anchor screws but with steel washer
replacing the elastomer washers.
Separate screws may be used in case
of inconvenience in the length of the
original anchor screws
iii) The template assembly shall l«
located with regard to level and
Page 1146 of 1427

alignment. It shall be ensured that
the top of the anchors lie. in a
horizontal plane at the required
elevation. The anchors shall be
tied/welded to reinforcements to
avoid displacement during
concreting.
iv)Concreting of the pedestal/pier cap
shall be done: to a level leaving a
gap of 25-50 mm below the
template.
v) The template and steel washers shall
be removed prior to placement of the
bearing assembly with temporary
clamps. The bearing assembly shall
be fitted to the anchors with the help
of anchor screws and elastomer
washers. Level at the bearing shall
be checked.
vi)The gap below the bearing assembly
shall be grouted with cement based
grout. Reference may be made to
Clause 2006.6.1 (vi).
B. Without Template with Gap
i) Pockets commensurate with the sizes

of the anchors shall be kept in
pedestals during concreting of the
same. The pedestal shall be cast
approximately 25 mm short of the
required finished level.
Page 1147 of 1427

ii) Anchors shall be fitted to the bearing
bottom with elastomer washers and
anchor screws. The bearing
assembly shall be seated in the
location on steel chairs/packs. The
anchors fitted below the bearing
shall go into pockets in the bed
block. Level and alignment of the
bearing shall be checked. It shall be
ensured that the bearing sits in a
horizontal plane.
iii) The gap below the bearing assembly
including anchor pockets shall be
grouted with cement based grout.
Reference may be made to Clause
2006.6.1
C. Without Template without Gap
Elongated pockets commensurate with the

sizes of the anchors shall be kept in pedestals during
concreting of the same. The geometry and location
of the anchor pockets (with tapered funnel extension,
if required) shall be such that after placement of the
bearing the pockets can be successfully grouted. The
pedestal shall be cast 5 mm - 15 mm short of the
required finished level. The required level shall be
achieved by chipping before placement of the
bearing. Careful control shall be exercised to cast at
the exact finished level or 1mm -3 mm down from
the required finished level.
Page 1148 of 1427

D. Seating of bearings shall be as per
manufacturer’s instructions.
2007. INSPECTION AND TESTING
Where any patents are used, the

manufacturer’s certificate with test proofs shall be
submitted along with the design and got approved by
the Engineer before their use in work.

ACCEPTANCE

with these specifications and shall meet the

specifications and shall meet the prescribed
Bearings shall be measured in numbers,

according to their capacities and particular
specifications given on the drawings.
The quantity of elastomeric bearings shall be

measured in cubic centimeters of finished
dimensions.
2010. RATE
Page 1149 of 1427

The contract unit rate of each type of bearing
shall include the cost of supplying and fixing the
bearings in position complete as specified on the
drawings or as decided by the Engineer.
The rate shall also include die cost of

samples and their testing when desired by the
Engineer.
In case of steel bearings the rate shall include

the cost of all nuts, bolts, the cost of all tests
prescribed in the specifications and shown on the
drawings.
Where the Department supplies the bearings,

the rate for fixing them shall include the cost of
anchor bolts, their fixing, transport of bearings from
the place of supply to the site, handling and placing
them in position as per direction of the Engineer.
Page 1150 of 1427

Open Foundations
2100
Open Foundations
Page 1151 of 1427

2101. DESCRIPTION
The work shall cover furnishing and

providing plain or reinforced concrete foundation
placed in open excavation, in accordance with the
drawings and these specifications or as directed by
the Engineer.
2102. MATERIALS
Materials shall conform to Section 1000 of

these Specifications. 2103. GENERAL
A method statement for construction

indicating the following shall be submitted by the
Contractor for approval of the Engineer, well in
advance of the commencement of Open foundation :
i) Sources of Material
ii) Design, election and removal of
formwork
iii) Production, transportation, laying, and
curing of concrete
iv) Personnel employed for execution and
supervision
v) Tests and sampling procedures
vi) Equipment details
vii) Any other point
Necessary arrangements for execution under

water wherever necessary, shall be- included in
method statement.
Page 1152 of 1427

Dimensions, lines and levels shall be set out
and checked with respect to permanent reference
lines and permanent bench mark.
2104. WORKMANSHIP
2104.1. Preparation of Foundations
Excavation for laying the foundation shall be

carried out in accordance with Section 300 of these
specifications. The last 300 mm of excavation shall
be done just before laying of lean concrete below
foundation.
In the event of excavation having been made

deeper than that shown on the drawing or as ordered
by the Engineer, the extra depth shall be made up
wkh MIS concrete in case of foundation resting on
soil and foundation grade concrete for foundations in
rock, at the cost of the Contractor and shall be
considered as incidental work. Special care shall be
taken not to disturb the bearing surface. Open
foundations shall be constructed in dry conditions
and the Contractor shall provide for adequate
dewatering arrangements to the satisfaction of the
Engineer.
2104.2. Setting Out
The plan dimensions of the foundation shall

be set out at the bottom of foundation trench and
checked with respect to original reference line and
axis. It shall be ensured that at no point the bearing
Page 1153 of 1427

surface is higher than the founding level shown on
the drawing or as directed by the Engineer.
2104.3. Construction
Where the bearing surface is earth, a layer of

Ml5 concrete shall be provided below foundation
concrete. The thickness of lean concrete layer shall
be 100 mm minimum unless otherwise specified.
No formwork is necessary for the lean

concrete layer. For foundation concrete work, side
formwork shall be used. Formwork for top of the
foundation concrete shall also be provided, if its top
has slopes steeper than 1 (vertical) to 3 (horizontal).
When concrete is laid in slope without top
formwork, the slump of the concrete shall be
carefully maintained to ensure that compaction is
possible without slippage down the slope of freshly
placed concrete. In certain cases it may be necessary
to build the top formwork progressively as the
concreting proceeds up the slope. Reinforcement
shall be laid as shown on the drawing.
Before laying of lean concrete layer, the earth

surface shall be cleaned of all loose material and
wetted. Care shall be taken to avoid muddy surface.
If any portion of the surface has been spoiled by
over-wetting, the same shall be removed. Concrete
M15 shall be laid to the thickness as required. No
construction joint shall be provided in the lean
concrete.
Page 1154 of 1427

Before laying foundation concrete, the lean
concrete or hard rock surface shall be cleaned of all
loose material and lightly moistened. Foundation
concrete of required dimensions and shape shall be
laid continuously upto the location of construction
joint shown on the drawing or as directed by the
Engineer.
Formwork and concrete shall conform to

Sections 1500 and 1700 respectively of these
specifications. Furnishing and providing steel
reinforcement shall conform to Section 1600.
The concrete surface shall be finished smooth

with a trowel. The location of construction joint and
its treatment shall be done as per requirements of
Section 1700. Formwork shall be removed not
earlier 24 hours after placing of concrete. Where
formwork has been provided for top surface, the
same shall be removed, as soon as concrete
hardened. Curing of concrete shall be carried out
by wetting formwork before removal. After its
removal, curing shall be done by laying not less than
10 cm of loose moistened sand, free from clod or
gravel and shall be kept continuously moist for a
period of 7 days.
Dewatering, where necessary for laying of

concrete, shall be carried out adopting any one of the
following procedures or any other method approved
by the Engineer:
Page 1155 of 1427

(i) A pit or trench deeper than the
foundation level as necessary may be
dug beyond the foundation pit during
construction so that the water level is
kept below the foundation level.
(ii) Water table is depressed by well
point system or other methods.
(iii) Use of steel/concrete caissons or sheet
piling for creating an enclosure for the
foundations, which can subsequently be
dewatered.
Before backfilling is commenced, loose sand

laid on foundation shall be removed and dispersed as
All spaces excavated and not occupied by the

foundation or other permanent works shall be
refilled with earth upto surface, of surrounding
ground in accordance with Section 300. In case of
excavation in rock, the annular space around
foundation shall be filled with M15 concrete upto the
top of rock.
The protective works, where provided shall

be completed before the floods so that the foundation
does not get undermined.

ACCEPTANCE
Page 1156 of 1427


No point of the surface of the lean concrete

in the case of foundation on soil or the surface of
hard rock in the case of foundation of hard rock,
shall be higher than the founding level shown on the
drawing or as ordered by the Engineer. Levels of the
surface shall be taken at intervals of not more than 3
metres centre to centre, subject to a minimum of nine
levels on the surface.
2106. TOLERANCES
(i) Variation in : ±25-mm

dimensions - 10 mm
(ii) Misplacement from : 15 mm

specified position in
plan
: 5 mm
(iii) Surface irregularities
measured with 3 m
straight edge : ±25 mm
(iv) Variation of levels at

the top
Page 1157 of 1427

2107. MEASUREMENT FOR PAYMENT
Excavation hi foundation shall be measured

in accordance with Section 300 based on the quantity
ordered or as shown on the drawing.
Lean concrete shall be .measured in cubic

metres in accordance with Section 1700, based on
the quantity ordered or as shown on the drawing.
Concrete in foundation shall be measured in

cubic metres in accordance with Section 1700, based
on the quantity ordered or as .shown on the drawing.
Reinforcement steel shall be measured in

tonnes in accordance with Section 1600, based on
the quantity ordered or as shown on the drawing.
2108. RATE
The contract unit rates for excavation in

foundation, lean concrete and concrete in foundation
and reinforcement steel shall include all works as
given in respective sections of these specifications
and cover all incidental items for furnishing and
providing open foundation as mentioned in this
Section.
Page 1158 of 1427

Sub-structure
2200
Sub-structure
Page 1159 of 1427

2201. DESCRIPTION

providing of masonry or reinforced concrete sub-
structure in accordance with the drawings and as per
these specifications or as directed by the Engineer.
2202. MATERIALS

there Specifications.
2203. GENERAL
A method statement for construction

indicating the following shall be submitted by the
Contractor for approval of the Engineer, well in
advance of the commencement of sub-structure :
(i) Sources of Materials

(ii) Design, erection and removal of
formwork
(iii) Production, transportation, laying and
curing of concrete
(iv) Personnel employed for execution and
supervision
(v) Tests and sampling procedures
(vi) Equipment details
(vii) Any other point
Arrangements for execution under water

wherever necessary, shall be included in method
Page 1160 of 1427

statement.
Dimensions, lines and levels shall be set .out

and checked with respect to permanent reference
lines and permanent bench mark.
2204. PEERS AND ABUTMENTS
Masonry, formwork, concrete and

reinforcement for piers and abutments shall conform
to relevant sections of these specifications. In case of
concrete piers, the number of horizontal construction
joints shall be kept minimum. Construction joints
shall be avoided in splash zones unless specifically
permitted by the Engineer and provided they are
treated in accordance with special provisions. No
vertical construction joint shall be provided. The
work shall conform strictly to the drawings or as
In case of tall piers and abutments, use of slip

form shall be preferred. The design, erection and
raising of slip form shall be subject to special
specifications which will be furnished by the
Contractor. The concrete shall also be subject to
additional specifications as necessary. All
specifications and arrangements shall be subject to
The surface of foundation/well cap/pile cap

shall be scrapped with wire brush and all loose
materials removed. In case reinforcing bars
Page 1161 of 1427

projecting from foundations are coated with cement
slurry, the same shall “be removed by tapping,
hammering or wire brushing. Care shall be taken to
remove all loose materials around reinforcements.
Just before commencing masonry or concrete work,
the surface shall be thoroughly wetted.
In case of solid (non-spill through type)

abutments, weep holes as shown on the drawings or
as directed by the Engineer, shall be provided in
conformity with Section 2706.
The surface finish shall be smooth, except the

earth face of abutments which shall be rough
finished.
In case of abutments likely to experience

considerable movement on account of backfill of
approaches and settlement of foundations, the
construction of the abutment shall be followed by
filling up of embankment in layers to the full height
to allow for the anticipated movement during
construction period before casting of superstructure.
2205. PIER CAP AND ABUTMENT CAP
Formwork, reinforcement and concrete shall

conform to relevant sections of these specifications.
The locations and levels of pier cap/abutment

cap/pedestals and bolts for fixing bearings shall be
checked carefully to ensure alignment in accordance
Page 1162 of 1427

with the drawings of the bridge.
The surface of cap shall be finished smooth

and shall have a slope for draining of water as shown
on the drawings or as directed by the Engineer. For
short span slab bridges with continuous support on
pier caps, the surface shall be cast horizontal. The
top surface of the pedestal on which bearings are to
be placed shall also be cast horizontal.
The surface on which elastomeric bearings

are to be placed shall be wood float finished to a
level plane which shall not vary more than 1.5 mm
from straight edge placed in any direction across the
area. The surface on which other bearings (steel
bearings, pot bearings) are to be placed shall be cast
about 25 mm below the bottom level of bearings and
as indicated on the drawings.
2206. DIRT/ BALLAST WALL, RETURN

WALL AND WING WALL
Masonry, concrete and reinforcement shall

conform to relevant sections of these specifications.
In case of cantilever return walls, no
construction joint shall generally be permitted
Wherever feasible, the concreting in cantilever
return walls shall be carried out in continuation of
the ballast wall.
For gravity type masonry and concrete return
Page 1163 of 1427

and wing wall, the surface of foundation shall be
prepared in the same manner as prescribed for
construction of abutment No horizontal construction
joint shall be provided. If shown on drawing or
directed by the Engineer, vertical construction joint
may be provided. Vertical expansion gap of 20 mm
shall be provided in return wall/wing wall at every
10 metre intervals or as directed by the Engineer.
Weep holes shall be provided as prescribed for
abutments or as shown on the drawings.
Formwork, reinforcement and concrete in

dirt/ballast wall shall conform to relevant sections of
The finish of the surface on the earth side

shall be rough while the front face shall be smooth
finished.
Architectural coping for wing wall/return

wall in brick masonry shall conform to section 1300.

ACCEPTANCE

with these specifications, and shall meet the

Page 1164 of 1427

2208. TOLERANCES IN CONCRETE
ELEMENTS
a) Variation in cross- : +10 mm, -5

sectional dimensions mm
b) Misplacement from
specified position in : 10 mm
plan
c) Variation of levels at : ±10 mm

the top
: ± 5 mm
d) Variations of reduced
levels of bearing areas
: ±10 mm
e) Variations from plumb
over full height
f) Surface irregularities
measured with 3m : 5 mm
straight edge
: 3 mm
All surfaces except
bearing areas
Bearing areas
Page 1165 of 1427

Masonry in sub-structure shall be measured
in cubic metres in accordance with Section 1300 or
1400, based on the quantities ordered or as shown on
the drawing.
Concrete in sub-structure shall be measured

in cubic metres in accordance with Section 1700,
based on the quantity ordered or as shown on the
drawing. No deduction shall be made for weep holes.
Steel in concrete of sub-structures shall be

measured in tonnes, in accordance with Section
1600, based on the quantity ordered or as shown on
the drawing.
Weep holes shall be measured as per Section

2700, based on the quantity ordered or as shown on
the drawings.
2210. RATE
The contract unit rates for masonry, concrete,

reinforcement and weep holes shall include all works
as given in respective sections of these specifications
and cover all incidental items for furnishing and
providing substructure as mentioned in this Section.
Page 1166 of 1427

Concrete Superstructure
2300
Concrete Superstructure
Page 1167 of 1427

2301. DESCRIPTION

providing of concrete superstructure in accordance
with the drawings as per these specifications or as
directed b) the Engineer.
2302. MATERIALS

2303. GENERAL
2303.1. A method statement for

construction, indicating the following, shall be
submitted by the Contractor for approval of the
Engineer, well in advance of the commencement of
the construction of superstructure :
(i) Sources of Materials

(ii) Design, erection and removal of
formwork
(iii) Production, transportation, laying and
curing of concrete
(iv) Prestressing system, if applicable
(v) Personnel employed for execution and
supervision
(vi) Tests and sampling procedure
(vii) Equipment details
(viii) Any other point
Page 1168 of 1427

2303.2. Dimensions, lines and levels shall
be set out and checked with respect to permanent
reference lines and permanent bench mark so that the
final product is in accordance with the drawings or
2303.3. The work shall conform to the

following sections besides stipulations in this section
with regard to specific type of construction:
(i) Formwork
(ii) Steel Reinforcement
(iii) Structural Concrete
(iv) Prestressing
Additionally, some of the common types of

superstructure construction shall have features as
discussed in this Section.
2304. REINFORCED CONCRETE

CONSTRUCTION
2304.1. Solid Slabs
Where adjacent span of slab has already been

cast, the expansion joint and filler board shall be
placed abutting the already cast span which shall
form the shutter on that side of the new span to be
cast The whole of the slab shall be cast with
reinforcement embedded for the road kerb and
railings. No other construction joint shall be allowed
except with the express permission of the Engineer.
Page 1169 of 1427

Where wearing coat is require! to be
provided, after the deck slab has been cast, the
surface of the slab shall be finished rough, but true to
lines and levels as shown on the drawings, before the
concrete has hardened. The areas of construction
joints shall be treated in the prescribed manner.
The top of the slab shall be covered with

clean moist sand as soon as the top surface has
hardened. Curing shall be carried out as per Section
1700.
Where the slab is resting on bearings, the

same shall be placed in position in accordance with
the drawings, before casting of deck slab.
2304.2. RCC T-Beam and Slab
Provision of construction joint shall conform

to the drawings or as per directions of the Engineer.
No construction joint shall be provided between the
bottom bulb and the web. If not indicated on the
drawing, construction joint may be provided at the
junction of the web and the fillet between the web
and the deck slab with the permission of the
Engineer.
The portions of deck slab near expansion

joints shall be cast along with reinforcements and
embedments for expansion joints. For this purpose,
the portion of deck slab near expansion joints may
Page 1170 of 1427

be cast in a subsequent stage, if permitted by the
Engineer.
The surface finish of the deck slab shall be

finished rough but true to lines and levels as shown
on the drawings before the concrete has hardened.
Care shall be taken for setting of bearings as
indicated on the drawings.
2305. PRESTRESSED CONCRETE

CONSTRUCTION
2305.1. PSC Girder and Composite RCC

Slab
PSC Girder may be precast or cast-in-situ as

mentioned on the drawing or as directed by the
Engineer. Girders may be post-tensioned or pre-
tensioned . Where precast construction is required to
be adopted, selection of casting yard and details of
methodology and of equipment for shifting and
launching of girders shall be included in the method
statement.
In case of cast-in-situ construction, the

sequence of construction including side shifting of
girders, if applicable, and placing on bearings shall
be in accordance with the drawings.
The PSC girder constituting the top flange,

web and the bottom flange shall be concreted in a
single operation without any construction joint.
Page 1171 of 1427

Engineer.

2305.2. Box Girder
Box girders may be simply supported or

continuous. Simply supported box girders shall have
minimum construction joints as approved by the
Engineer. In the case of continuous box girders the
sequence of construction and location of
construction joints shall strictly follow the drawings.
The box section shall be constructed with a

maximum of one construction joint located in the
web below the fillet between the deck slab and web.
If permitted by the Engineer, one additional
construction joint may be permitted and this
construction joint shall be located in the web above
the fillet between the soffit slab and web.
Page 1172 of 1427

Engineer.

2305.3. Cantilever Construction
Continuity of untensioned reinforcement

from one segment to the next must be ensured by
providing full lap length as necessary.
The design of the superstructure shall take

into account the following aspects which form an
integral pan of the construction operations :
a) Stability against over-turning for each

statical condition through which the
assembly passes, shall be checked.
b) Stresses at each preceding segment joint
with the addition of every segment or
change of statical conditions shall be
checked. The load of equipment as well
as construction live load shall be taken
into account
c) Precambering of the superstructure
Page 1173 of 1427

during construction shall be done in such
a manner that the finally constructed
structure under permanent load attains
the final profile intended in the drawings.
2306. TOLERANCES
2306.1. Precast Concrete Superstructure
Variation in cross-sectional dimensions :

a) upto and including 2m
: ± 5 mm
over 2m
: ± 5 mm
b) Variation in length overall and
: shall not exceed
length between bearings
±10 mm or ±0.1
per cent of the
span length, which-
ever is lesser
c) Permissible surface irregularities
when measured with a 3 m straight
edge or template
: 5mm
2306.2. Cast-in-Situ Superstructure
a) Variations in, thickness of top and
Page 1174 of 1427

: -5mm to ±10mm
bottom slab for box girders, top
and bottom flange for T-girders or
slabs
b) Variations in web thickness
: -5mm to ±10mm
c) Variations in overall depth or width
: ±5mm
d) Variation in length overall and length
: shall not exceed
between bearings
: ±10mm to ±0.1
per cent of the
span length, which-
ever is lesser
e) Permissible surface irregularities
when : 5mm
measured with a 3 m straight edge
or template

ACCEPTANCE


Page 1175 of 1427

Concrete in superstructure shall be measured

in accordance with Section 1700, based on the
quantity ordered or as shown on the drawings.
Steel reinforcement (untensioned) in

superstructure shall be measured in accordance with
Section 1600, based on the quantity ordered or as
High tensile steel (prestressing) in

superstructure shall be measured in accordance with
Section 1800, based on the quantity ordered or as
2309. RATE
The contract unit rates for concrete, steel

reinforcement (untensioned) and high tensile steel
(prestressing) shall include all works as given in
respective sections of these specifications and cover
all incidental items for furnishing and providing
superstructure as mentioned in this section.
Surface and Sub-surface Geotechnical

Exploration
2400
Page 1176 of 1427

Surface and Sub-surface
Geotechnical Exploration
Page 1177 of 1427

2401. GENERAL
2401.1. The objective of sub-surface

exploration is to determine the suitability or
otherwise of the soil or rock surrounding the
foundation and soil parameters and rock
characteristics for the design of foundation by in-
situ testing or testing of samples/cores taken out of
exploration. The sub-surface exploration shall be
planned in such a way that different types of soil
upto the desired depth and their profile for the full
proposed length of the bridge can be recorded
and other information such as mechanical and
physical properties like grain-size distribution, sen-
sitivity, any existence of deleterious material in
soil or ground water, etc., are determined along with
soil parameters and rock characteristics. The sub-
surface exploration shall also throw light on porosity
of rock and subsidence due to mining, ground water
level, artesian condition, if any, likely sinking and
driving effort, likely constructional difficulties,
etc.
2401.2. Field Investigation
A Field investigation of sub-surface has

usually three phases :
i) Reconnaissance
ii) Preliminary Exploration;
iii) Detailed Explorations
2401.2.1. Reconnaissance includes a
Page 1178 of 1427

review of available topographic and geological
information, aerial photographs and data from
previous investigations and site examination.
2401.2.2. Preliminary investigation shall

include the study of existing geological
information, previous site reports, geological maps,
air photos, etc. and surface geological examination.
For large and important structures the information
may be supplemented by geophysical methods. In
some cases where no previous sub-strata data are
available, exploratory geophysical investigation
may need to be supplemented by resorting to a few
bore-holes. These will help to narrow down the
number of sites under consideration and also to
locale the most desirable location for detailed sub-
surface investigation like bore or drill holes,
sounding probes, etc.
2401.2.3. The scope of detailed

investigation for bridges may be decided based on
data obtained after preliminary investigation. Based
on data obtained after preliminary investigations, the
bridge site, type of structure with span arrangement
and the location and type of foundations, shall be
tentatively decided. Thereafter, the scope of detailed
investigation including the extent of exploration,
number of bore-holes, type of soundings, type of
tests, number of tests, etc., shall be decided, so that
adequate data considered to be necessary for the
detailed design and execution, are obtained.
Page 1179 of 1427

2401.2.4 The width of exploration : One
purpose of detailed exploration for high
embankments is to ascertain the average shear
strength of each strata. The other purpose is to
ascertain the compressibility of the clayey strata. It
is, therefore, necessary that detailed and well
illustrated description of the characteristics of
stratification should be prepared. After the general
shape and trend of the boundaries of the various soil
deposits have been determined and rough assessment
of their strength has been made by sub-surface
sounding, with or without sampling in exploratory
boring, the location of bore-hole(s) for undisturbed
sampling shall be decided. At least one
representative undisturbed sample should be
collected from each strata. When the homogeneous
strata is very thick, one representative sample shall
be collected for each 3 m thickness of the strata.
2401.3. Soil investigation for foundations

shall contain a programme for boring and retrieval of
samples. The field work shall consist of excavation,
drilling of bore-holes for the purposes of collection
of undisturbed and disturbed samples, standard
penetration tests, in-situ vane tests, static and
dynamic cone penetration tests, other field tests, as
specified by the Engineer and preparation of bore-
logs. Collection and preservation for testing of-
disturbed and undisturbed samples from boreholes,
borrow pits, etc., as specified by the Engineer shall
form a part of the above. All in-situ tests shall be
supplemented by laboratory investigations. Relevant
Page 1180 of 1427

Indian Standards such as IS: 1498, IS: 1888,
15:1892, 15:2131, IS:2132, IS:2720, IS:4434 and
15:4968 and Appendix I of IRC:78, etc., shall be
followed for guidance.
2401.4. The soundings by dynamic

method shall be carried out in bore-holes using a
standard sampler as specified in IS:2131.
2402. PRELIMINARY INVESTIGATION
2402.1. Foundations
2402.1.1. Preliminary exploration shall be

carried out to determine the soil profile showing the
boundaries between the different soil types and
between loose and dense parts in the same type of
deposits.
For guidance reference may be made to

IRC:75. For this purpose, as a first step, a suitable
type of sub-surface sounding (e.g. static or dynamic
cone penetration test) shall be carried out. As many
soundings as necessary should be made, until the
penetration data is complete enough to leave no
doubt concerning the general shape and the trend of
boundaries of the various soil deposits. Exploratory
drill holes should then be made at one or two
locations where average condition prevails and near
those few points where the penetration diagrams
indicate maximum deviations from the average.
Page 1181 of 1427

2402.1.2. The exploration shall cover the
entire length of the bridge and also extend at either
side for a distance about twice the depth below bed
of the last main foundations. If there is any necessity
for designing investigation for approaches
particularly on soft soil or with high embankment or
there is a possibility of considering alternatives
between viaduct or earthen embankment, the
extended length and location of the borings
beyond the proposed location of abutment should
be determined and executed.
2402.1.3. The depth of exploration should

be at least 1½ times the minimum width of
foundation below the proposed foundation level.
Where such investigation end in any unsuitable or
questionable foundation material the exploration
shall be extended to a sufficient depth into firm
and stable soils or rock but not less than four times
the minimum depth of foundation below the earlier
contemplated foundation level. In case of good
sound rock the stipulation of minimum depth may
be decreased based on difficulty to conduct core
drilling and the minimum depth may be restricted
to 3 metres.
2402.2. Guidebund and Embankment
The depth of exploration should include all

strata likely to affect stability of the embankment,
guide bund and/or cause undesirable settlement. In
general, the requirement of settlement governs the
Page 1182 of 1427

depth of exploration for high embankments in
particular. However, borings can be terminated at
shallower depths when firm strata or bed rock is
encountered. Ordinarily, the boring shall be taken to
a depth of at least 1.5 times the height of
embankment and guidebund. However, where highly
compressible strata arc encountered, the boring may
have to be taken deeper. In order to ensure that firm
strata is sufficiently thick, the boring should extend 3
metre into the firm strata.
2403. DETAILED EXPLORATION
2403.1. The exploration shall cover the

entire length of the bridge and also extend at either
end for a distance of about twice the depth below
bed of the last main foundation to assess the effect of
the approach embankment on the end foundations.
Generally the sub-surface investigations
(preliminary and detailed) for bridges shall extend to
a depth below the anticipated foundation level
equal to about one and a half times the width of the
foundation. However, where such investigations end
in any unsuitable or questionable foundation
material, the exploration shall be extended to a
sufficient depth into firm and stable soils or to rock.
2403.2. The type and extent of exploration

shall be divided into the following groups as per
requirement of foundation design and likely
method of data collection:
Page 1183 of 1427

(i) Foundation requiring shallow
depth of exploration
(ii) Foundation requiring large
depth of exploration
(iii) Fills behind abutments and
protection works
2403.3. Location Boring
Where the data made available by detailed

exploration indicates appreciable variation or where
variations in a particular foundation are likely to
appreciably affect the construction (specially in case
of bridge foundations resting on rock), it will be
necessary to resort to additional bores/soundings to
establish complete profile of the underlying strata.
The additional borings /soundings shall be decided
depending upon the extent of variation at a particular
foundation location and should cover the entire area
of the particular foundation.
2403.4. Construction Stage Exploration
Whenever a change in the sub-soil strata/rock

profile is encountered during construction,
explorations shall be resorted to establish the correct
data for further decisions.
2403.5. Logging of bore-holes by radio-

active methods shall be done for detailed
investigations as specified in the contract or in
special provisions.
Page 1184 of 1427

2403.6. For bridge works, the investigations
shall be comprehensive enough to enable the
designer to estimate or determine the following :
(i) the engineering properties of the
soil/rock,
(ii) the location and extent of soft layers
and gas pockets, if any, under the hard
founding strata,
(iii) the geological, condition like type of
rock, faults, fissures or subsidence due
to mining, porosity etc.,
(iv) the ground water level,
(v) artesian conditions, if any,
(vi) quality of water in contact with the
foundation,
(vii) The depth and extent of scour.
(viii) suitable depth of foundation,
(ix) the bearing capacity of the foundation,
(x) probable settlement and probable
differential settlement of the
foundations,
(xi) likely sinking or driving effort, and
(xii) likely construction difficulties.
2404. EXPLORATION FOR BRIDGE

FOUNDATIONS RESTING ON ROCK
2404.1. Investigation and interpretation

of data for rock a specialised work. To arrive at
the characteristic strength of rock mass, reliance
shall be placed more on in-situ tests in
Page 1185 of 1427

comparison to laboratory tests. An engineering
geologist shall also be associates in the exploration
programme.
2404.2. Identification and classification of

rock types for engineering purposes may in general
be limited to broad, basic geological classes in
accordance with accepted practice. Strength of
parent rock alone is of limited value because
overall characteristics depend considerably on
character, spacing and distribution of
discontinuities of the rock mass, such as the joints,
bedding planes, faults and weathered seams. An
important factor affecting the behaviour is the
weathered zone at top.
2404.3. Basic Information Required from

Explorations
(i) Depth of rock strata and its variation

over the site,
(ii) Whether isolated boulder or massive
rock formation,
(iii) Extent and character of weathered zone,
(iv) Structure of rock - including bedding
planes, faults, fissures, solution cavities
etc.,
(v) Properties of rock material-strength,
geological formation, etc.,
(vi) Erodibility of rock to the extent possible,
(vii) Colour of water.
Page 1186 of 1427

2404.4. Exploration Programme
If preliminary investigations have revealed

presence of rock (within levels where the
foundation is to rest, it is essential to take up ailed
investigation to collect necessary information
mentioned in 2404.3. The exploratory bore-hole
shall be drilled into the rock a depth of about 3
metres to distinguish a boulder from a continuous ck
formation.
2404.5. The extent of exploration shall be

adequate enough to give a complete picture of the
rock profile both in depth and across channel width
to assess the constructional difficulties in reaching
the foundation levels.
2404.6. The depth of boring in rock

depends primarily on local geology, credibility of
the rock, extent of structural loads to be
transferred to foundation etc. Normally, it shall pass
through the upper weathered or otherwise weak
zone, well into the sound rock. Minimum of boring
in sound rock shall be 3 metres.
2404.7. Detailed Investigation for Rock
2404.7.1. This covers sounding, boring and

drilling. An adequate investigation programme
shall be planned to cover the whole area for general
characteristics and in particular the foundation
location, to obtain definite information regarding
rock-depth and its variation over foundation area.
Page 1187 of 1427

The detailed programme of exploration will depend
on the type and depth of over-burden, the size and
importance of the structure, etc. To decide
this, geophysical methods adopted at the
preliminary investigation stage will be helpful, this
data being supplemented by sounding, bore-holes
and drill holes.
2404.7.2. Drilling through rock is a very

specialised work and every shall be taken to
notice and record any small change during
drilling. The lime required to drill through a
certain depth, amount of core recovery, physical
condition, length of pieces of core, joints, colour of
water residue, weathering and evidence of
disturbance and effects shall be carefully noticed
and entered in the drilling log For guidance,
IS:5313 may be referred to. The data shall be
presented in accordance with IS:4464.
2404.7.3. The cores shall be stored properly

in accordance with IS:4078.
2404.7.4. The rock cores obtained shall be

subjected to following laboratory tests :
(i) Visual identification for texture.
structure, composition, colour and grain
size,
(ii) Laboratory tests shall be done for
specific gravity, porosity and moisture
content.
Page 1188 of 1427

2404.7.5. In-situ tests shall be made in
accordance with IS:7292; IS:7317; and IS:7746. In
addition, laboratory tests can also be made on
samples.
2404.7.6. Use of in-situ tests for measuring

strength and deformation characteristics shall be
made. Use of bore-hole photography will be
desirable to evaluate the presence of faults,
fissures or cavities, etc.
2404.8. Special Cases
2404.8.1. Investigation for conglomerate :

A drill hole shall be made same as for rock. The
samples collected shall be subjected to suitable tests
depending upon the material, special care shall be
taken to ascertain erodibility of the matrix. Where
possible, specially for shallow foundation, Plate
Load Test shall be conducted.
2404.8.2. Investigation for laterites : The

investigation shall be generally similar to that
required for cohesive soils, use of penetration tests
shall be preferred, if suitable correlation charts are
available. This may be static or dynamic
penetration tests or vane shear tests. In the case of
hard laterite, recourse may have to be made to core
drilling as for soft rocks. For laterites at shallow
depths, use of Plate Load Test may be
advantageous.
Page 1189 of 1427

2404.9. Caution
2404.9.1. The interpretation of laboratory

results on rock samples depends upon the
relationship of the specimens tested to the overall
rock characteristics, enumerated in Appendix .1 of
IRC:78. For this purpose, care shall be exercised in
the choice of specimen size and its orientation in
relation to the joint pattern.
2404.9.2. In some cases, the foundation

behaviour will be dominated by a possible mode of
failure involving movement along some joint
surface, fissures or weak layer within a generally
strong rock system and also by possible weathering.
In-situ shear tests may be conducted wherever
feasible, as such tests are likely to give mere
representative data than the shear tests conducted on
core samples.
2404.10. Presentation of Data
The data shall be given in diagrammatic form

in 3 sheets giving the following details :
Sheet 1 : Plan showing the position of bore-
holes clearly marked so as to fix the position at a
future date.
Sheet 2 : This shall contain the bore-log chart

and test results of the samples separately for each
bore-hole/pit etc.
Page 1190 of 1427

Sheet 3 : This shall contain pictorial
representation of the bore-log data to get an overall
picture of the soil profile at the cross-section of the
river.
NOTE : For guidance, refer to IRC:78.
2405. BORING
Boring shall be done by any of the following

methods depending on the soil type and types of
samples required for the investigation:
i) Auger Boring
ii) Shell and Auger Boring
iii) Percussion Boring
iv) Wash Boring
v) Rotary Boring
For preliminary and detailed sub-surface

investigation only rotary drills shall be used. The
casing shall also be invariably provided with
diameters not less than 150 mm upto the level of
rock, if any. However, use of percussion or wash
boring equipment shall be permitted only to
penetrate through bouldery or gravelly strata for
progressing the boring but not for the collection of
samples. While conducting detailed borings, the
resistance to the speed of drilling i.e. rate of
penetration, core loss, etc., as already specified in
Appendix 3 of IRC:78 shall be carefully recorded to
evaluate the different types of strata and to
Page 1191 of 1427

distinguish specially sand from sandstone, clay from
shale, etc.
2406. RECORDS OF BORINGS AND

TRIAL PITS
2406.1. The field records for the preliminary

and detailed exploration shall contain the date when
the boring was made, the location of the boring with
reference to a permanent system of co-ordinates and
the elevation of the ground surface with respect to a
permanent bench mark. They shall include elevation
at which the water table and the upper boundary of
each of the successive soil strata were encountered,
the investigator’s classification of the layer on the
basis of general information obtained from field
examination (refer to Appendix 2.1 of IRC:75) and
the value of the resistance obtained by means of
Standard Penetration Test The type of tools used for
borings shall be recorded. If the tools were changed,
the depth at which the change was made and the
reason thereof shall also be noted. Incomplete and
abandoned borings shall be described with no less
care than successfully completed drill holes. The
notes shall contain everything of significance
observed on the job such as the elevation at which
wash water was lost from the hole.
2406.2. For all borings and trial pits,

necessary information as detailed below shall be
given. A site plan showing the disposition of the
bore holes shall also be attached:
Page 1192 of 1427

a) Agency
b) Location with reference map
c) Pit/Bore-hole number
d) Reduced level (R-L.) of ground
surface or other reference point
e) Dates of starting and completion
f) Name of supervisor
g) Scales of plans and sections
h) Dimensions, methods of advancing
exploration such as by hand tools,
blasting, boring, etc.
i) General description of strata met with
and RLs at which they arc met
j) Position and altitude of contacts,
faults, strong joint, slicken sides, etc.
k) Inflow of water, methods of controlling
the water, required capacity of pumps
for dewatering
l) The level at which the sub-soil water is
met with
m) Dip and strike of bedding and of
cleavage.
n) Visual description of strata
o) Results of field tests e.g. SPT, in-situ
vane shear test etc.
p) Any other information and remarks.
24063. Upon removal of sampling tube, the

length of the sample in the tube and the length
between the top of the tube and the top of the sample
in the tube shall be measured and recorded.
Page 1193 of 1427

2407. METHODS OF SAMPLING
There are two types of samples viz.

(a) Disturbed sample
(b) Undisturbed sample. The usual methods
for sampling conforming to IS:1892 and IS:2132
are given below :
Nature of Ground Type of Sample Method of Sam

Soil Disturbed Hand Samples
Auger Samples
Shell Samples
Undisturbed Hand Samples
Tube Samples
Rock Disturbed Wash Samples
rotary drilling
Undisturbed Cores
2408. PROCEDURE FOR TAKING SAMPLES
2408.1. For proper identification of sub-

surface material, sample should be recovered
containing all the constituents of the materials in
their proper proportion. In clayey deposits such
samples could be collected by split spoon samplers.
In the case of sandy deposits, sampling spoons shall
be fitted with suitable devices for retaining
samples. All data required for soil identification
(Appendix 2.1 of IRC:75) should be collected from
the samples so extracted when undisturbed
samples, which are more desirable for collection
Page 1194 of 1427

of some of the data, are not available. Penetration
test should be carried out with the standard split-
spoon sampler or penetrometers if the soil is coarse
grained. When it is known in advance that the soil
profile is fairly regular, preliminary and detailed
investigation may be combined. Tube samplers can
be used in place of split spoon samplers for
collecting samples in clayey strata.
2408.2. Disturbed Soil Samples
2408.2.1. Disturbed samples of soil shall

be obtained in the course of excavation and
boring. For procuring samples from below the
ground water level, where possible, special type of
sampler shall be used. Where Standard
Penetration Test is conducted, representative
samples shall be obtained from the split spoon.
While collecting disturbed samples from borrow
areas it shall be ensured that the samples collected
represent all types of borrow materials to be used
in the construction of embankment and sub-grade.
2408.2.2. The size of sample generally

required shall be as given in Table 2400-1.
TABLE 2400-1 SIZE, OF SOIL SAMPLE

REQUIRED
S. PURPOSE OF SOIL WEIGHT

NO. SAMPLE TYPE OF
SAMPLE
Page 1195 of 1427

REQUIRED
Kg
1 Soil Cohesive 1
identification, soils
natural moisture Sands and 3
content tests, Gravels
mechanical
analysis and
index properties,
chemical tests
2. Compression Cohesive
tests soils and 12.5
sand
3. Comprehensive Cohesive 25 - 50
examination of soils and
construction sands 50 - 100
material and Gravelly
borrow area soil soil
including soil
stabilisation
24082.3. While taking out disturbed soil

samples, Standard Penetration Test may also be
conducted to find out the bearing capacity of the
sub-soils at specified, levels.
24083. Undisturbed Soil Samples
24083.1. The location of the bore-hole

shall be as indicated on the drawing or given by
the Engineer.
Page 1196 of 1427

The depth of the bore-hole shall be as
indicated on the drawing or shall be governed by the
criteria given therein or as directed by the Engineer.
24083.2. Samples shall be obtained in such a

manner that their moisture content and structure do
not get altered. This may be ensured by careful
protection and packing and by use of correctly
designed sampler.
24083.3. Standard Penetration Test may

have to be conducted in each case to obtain
additional data as directed by the Engineer. In soft
clay, in-situ vane shear test as per IS:4434 may have
to be conducted. Where all the three operations have
to be carried out in one layer, the sequence shall be
undisturbed soil sampling followed by in-situ vane
shear test, followed by Standard Penetration
Test.
24083.4. For compression test samples, a

core of 40 mm diameter and about 150 to 200 mm
length may be sufficient, but for other laboratory
tests, a core of 100 mm diameter and 300 mm length
shall be taken as far as possible, unless otherwise
specified by the Engineer.
2408.3.5. The upper few millimetres of both

types of sample shall be rejected as the soil at the
bottom of the bore hole usually gets disturbed by the
boring tools.
Page 1197 of 1427

2408.4. Rock Samples
2408.4.1. Disturbed samples : The sludge

from percussion borings or from rotary borings
which have failed to yield a core, shall be collected
for a disturbed sample, it may be recovered from
circulating water by settlement in a trough.
2408.4.2. Undisturbed samples : Block

samples taken from the rock formation shall be
dressed to a size of about 90 x 75 x 50 mm.
For core samples - cores of rock shall be
taken by means of rotary drills Fitted with a coring
bit with core retainer, if warranted.
2408.4.3. In case of rock at shallow

depths which can be conveniently reached, test
pits or trenches are the most dependable and
valuable methods since they permit a direct
examination of the surface, the weathered zone and
presence of any discontinuities. It is also possible to
take representative samples for tests. For guidance,
IS:4453 may be referred to.
2409. PROTECTION, HANDLING AND

LABELLING OF SAMPLES
2409.1. Care shall be taken in handling and
labelling of samples so that they are received in a fit
state for examination and testing and can be
correctly identified as coming from a specified trial
pit or boring.
Page 1198 of 1427

2409.2. The disturbed material in the upper
end of the lube shall be completely removed before
applying wax for sealing. The length and type of
sample so removed should be recorded.
2409.3. The soil at the lower end of the

tube shall be reamed to a distance of about 20
mm. After cleaning, both ends shall be sealed with
wax applied in a way that will prevent wax from
entering the sample. Wax used for sealing should not
be heated to more than a few degrees above its
melting temperature. The empty space in the
samplers, if any, should be filled with moist soil,
saw dust, etc., and the ends covered with tight
fitting caps.
2409.4. Labels giving the following

information should be affixed to the tubes :
a) Tube number
b) lob designation
c) Sample location
d) Boring number
e) Sample number
f) Depth
g) Penetration
h) Gross recovery ratio
The tube and boring numbers should be

marked in duplicate. Duplicate markings of the
boring number and sample number on a sheet
which will not be affected by moisture should be
Page 1199 of 1427

enclosed inside the tube.
2410. TESTS FOR EXPLORATION OF

SHALLOW FOUNDATIONS OF BRIDGES
2410.1. Test pits or trenches are the most

dependable and valuable methods of exploration
since they permit direct visual examination and
more reliably the type of soil and their stratification.
This will also allow in-situ tests like plate bearing
tests, shear tests and uni-axial jacking tests, etc.
2410.2. Tests shall be conducted on

undisturbed samples, which may be obtained from
open pits. The use of Plate Load Test (as per
15:1888) is considered desirable to ascertain die
safe bearing pressure and settlement characteristics.
A few exploratory bore holes or soundings shall be
made to safeguard against presence of weak strata
underlying the foundation. This shall extend to a
depth of about W2 times the proposed width of
foundation.
The laboratory results shall correlate with

in-situ tests like Plate .Load Tests and Penetration
Test results.
2411. TESTS FOR EXPLORATION FOR

DEEP FOUNDATIONS OF BRIDGES
2411.1. The tests to be conducted at various

locations for properties of soil, etc., are different for
Page 1200 of 1427

cohesive and cohensionless soils. These are
enumerated below and shall be carried out, wherever
practicable, according to soil type.
2411.1.1. Cohesion less soil
a) Classification tests, density, etc.

b) Field tests.
 Plate Load test as per IS: 1888.
 Dynamic Penetration test as per
IS:2131 and Use of Dynamic Cone
penetration test as per 15:4968 (Part
1 or Part 2) may be conducted
where considered appropriate
c) Laboratory tests : Shearing strength test
- triaxial or box shear test - in case of
the possibility of rise of water table, the
tests shall be done or. saturated
samples.
2411.12. Cohesive soils
a) Classification tests, density, etc.

b) Field tens :
 Plate Load Test.
 Unconfined Compression Test as
per IS:2720 (Part 10).
 Vane Shear Test as per IS:4434.
 Static Cone Penetration Test
(IS:4968 Part 3)
c) Laboratory tests : Shearing strength lest
- triaxial tests (1S:2120 Part 9).
Page 1201 of 1427

Consolidation Test (IS:2720 Part 15)
Note : Where dewatering is expected,

samples may be tested for permeability (IS:2720
Part 17).
2411.2. The sub-surface exploration for

bridge works can be divided into 3 zones:
a) between bed level and upto anticipated

maximum scour depth (below H.F.L.)
b) from the maximum scour depth to the
foundation level.
c) from foundation level to about 1 and
half times the width of the foundation
below it.
2411.3. The sub-soil water shall be tested for

chemical properties to ascertain the hazard of
deterioration to foundations. Where dewatering is
expected to be required, permeability characteristics
shall be determined.
2411.4. For the different zones categorised in

para 2411.2 the data required, such as soil
classification, panicle size distribution, shearing
strength characteristics, method of sampling
disturbed and undisturbed samples, testing, including
particle size distribution, shear strength, un-confined
compression test, shall be complied with.
2412. TESTING OF MATERIAL FOR GUIDE
Page 1202 of 1427

BUND AND HIGH EMBANKMENT AND ITS
FOUNDATIONS
2412.1. The soil properties for the

embankment foundation shall be as specified in
particular specifications and shall be got verified
prior to construction operation. In case the actual soil
properties do not match the particular specification,
then embankment design shall be revised.
2412.2. Field investigation for the

embankment material should be carried out to collect
general information as indicated in IRC:75. For
details refer to Clause 305.
Field investigations for sub- soil strata shall

‘consist of taking minimum two bore holes for each
approach to a bridge along centre line of the
alignment at a distance of 50 m and 120 m behind
the abutment positions on both sides. The depth of
bore holes below the ground level may ordinarily be
2.5 times the maximum height of the embankment
subject to minimum depth of 20 m. Thin walled
sampling tubes of 100 mm internal diameter and 450
mm minimum length conforming to IS:2132 shall be
used for collecting undisturbed samples from bore-
holes at an interval of 2.5 to 3.5 m. Standard
penetration test should be conducted immediately
after undisturbed sample is collected.
2412.3. In addition to the relevant

identification tests, mentioned in IRC:75, it shall be
Page 1203 of 1427

necessary to conduct some of the following tests on
the undisturbed samples collected from the sub-
strata. The choice of test is primarily determined by
the type of soil, type of stability analysis (vide Table
2400-2), availability of apparatus and cost of
investigation.
TABLE 2400-2 SHEAR STRENGTH TESTS

FOR STABILITY ANALYSIS
S. Stage in Life Strength Shear Test
No. of Embankment Parameters
1 a) During Unconsolidatcd undrained
construction or triaxial shear test on
immediate post- c
uu, uu undisturbed samples and
construction compacted embankment
material
1 b) — do — Unconfined compression
Su laboratory or vane shear t
1 c) During C‘ Consolidated undrained t

construction or with pore-pressure
immediate post- measurement on as
construction compacted soil samples o
embankment materials a
undisturbed samples
2 Long term stability C‘ — do —
Page 1204 of 1427

2412.4. Laboratory Investigations of
Embankment Material
2412.4.1. The following tests should be

conducted on representative samples of embankment
material
S. NO. TEST T
i) Gradation Test (Sieve Analysis) IS
ii) Atterberg Limit Test IS
iii) Standard Proctor Test IS
iv) Natural Moisture Content IS
2412.4.2 In addition to the above, there is

need for shear strength tests on compacted samples
of the fill material. For this purpose, the relative
compaction should be 95 per cent of the Standard
Proctor maximum dry density and moisture content,
same as that likely to prevail in the embankment
during the period covered by the stability analysis or
to be used in the field during construction.
Undrained test shall be run on cohesive soils and
shear strength parameters should be ascertained for
the ranges of normal pressures which are likely to be
experienced in the field. In cases where effective
stress analysis is required to be done, pore-pressure
measurements should also be made during the
undrained tests and effective strength and pore-
pressure parameters should be found out. For fill
material of cohesionless soils, a direct shear box test
(IS:2720-Part 13) may be conducted to ascertain
shear strength of soil.
Page 1205 of 1427

2412.4.3. The results of reconnaissance, field
and laboratory investigations for embankments shall
be consolidated into a well-knit report. The record of
findings and recommendations, if any, may be pre-
sented in the form of written test, graphs, figures and
tables, as appropriate for different types of data and
findings.
Information and data to be contained in the

report should include general location map, pertinent
geological information on reconnaissance
observations, sub-soil profile (Fig. 2.1 of IRC:75),
boring logs and summary of sub-soil properties (Fig.
2.2 of IRC:75), graphs, and tables related to
laboratory investigations, results of borrow area
investigations (Fig. 2.3 of IRC:75) and
recommendations, if any.
The undisturbed samples shall be collected

from each layer of sub-soil unless the stratum is such
that undisturbed samples cannot be collected using
ordinary sampler. Where indicated by the Engineer,
undisturbed samples shall be collected using piston
sampler or core-cutter or such special devices. In
thick layers undisturbed samples shall be collected at
3 m interval.
In case of bridge and road structures, the

work of boring and trial pits shall be considered as
incidental to the foundation works and nothing extra
Page 1206 of 1427

shall be paid unless otherwise specified in the
contract In cases where it is specified to be paid
separately, like contract for soil investigation, the
work shall be measured in running metres for boring,
in cubic meters for trial pits, in number of samples
for collection of disturbed and undisturbed samples
and in number of tests for each type of test.
2414. RATE
The contract unit rate shall include the cost of

all labour, materials, tools and plant and equipment
required for doing the boring or making pits as per
these specifications, taking out and packing the
samples, sending and getting them tested in
approved laboratories and making available the test
report as specified or directed by the Engineer
inclusive of all incidental costs to complete the work
as per the specifications.
Page 1207 of 1427

River Training Work and Protection
Work
2500
River Training Work and
Protection Work
Page 1208 of 1427

2501 DESCRIPTION
River training and protection work shall

include construction of guide bunds, guide walls,
bank protection, flooring and approach embankment
protection as required for ensuring safety of the
bridge structure and its approaches against damage
by flood/flowing water. Construction of various
components shall conform to IRQ89 and these
2502. GUIDE BUND

construction of embankment of guide bund and
provision of pitching/rivetment on slopes, apron,
toe protection, curtain walls etc. as indicated on the
drawing in accordance with these specifications or as
The provisions given hereunder are

applicable only to guide bunds for bridges across
alluvial rivers. Guide bunds for bridges across
submontane rivers shall call for supplemental
specifications.
2502.2. The alignment and layout of guide

bund shall be as indicated on the drawing or as
approved by the Engineer. The construction of
embankment for guide bund shall conform to
provisions of Section 300 of these Specifications.
Pitching, filter underneath pitching and turfing,
Page 1209 of 1427

apron, toe protection, curtain walls, etc., shall be as
per these specifications.
2502.3. Guide bunds shall generally be made

of locally available materials from the river bed
preferably cohesionless materials. Trial pits shall be
taken in borrow holes to examine suitability of soil
for construction and also to decide the types of earth
moving machinery to be arranged. The borrow
pits should be sufficiently away from the location
of the launching apron. No borrow pits should be
dug on the river side of the guide bunds.
Construction of guide bund shall be taken in

hand along with the construction of the bridge.
Every effort shall be made to complete the work of
the guide bund in one working season. Where there
is any doubt about completion of the whole guide
bund within one working season, suitable measures
shall be planned and executed for protection of
completed work. In such cases the construction of
guide bund shall be started from abutment towards
upstream.
2502.4. Construction of apron and pitching of

the guide bunds shall generally conform to clause
2503 and 2504 of these Specifications. Sufficient
length of pit along the guide bund shall be ready
within one to two months of commencement of
work so that the placing of stones in the apron and
in the slope pitching can be commenced. As a
guideline, earthwork should be completed within
Page 1210 of 1427

80 per cent of working season and about 70 per
cent working season shall be available for laying
apron and pitching. No portion of the guide bund
should be left below HFL before the onset of
monsoon. Bottom of apron pit shall be as low as
permitted by sub-soil water/lowest water level.
Sufficient labour and appropriate earth moving
machinery and trained staff shall be deployed in
construction.
2502.5. The Contractor shall furnish his

planning for approval of die Engineer regarding
transport of stones from the quarries to the site of
work taking into account the quantities of stone
required to be transported every day, -train/truck,
etc., deployed, available ferry or boats and labour
available for loading and unloading and for laying
within the time frame for construction of guide bund.
Adequate reserve of stones j should be maintained
for major works as decided by the Engineer.
{Reserve stones shall be stacked far away from the
main channel of ‘the river.
2502.6. Where the alignment of guide

bund or the approach J embankment crosses a
branch channel of the river, the branch channel may
be either diverted to the main channel of the river
with the help of spurs, etc. or closed by a properly
designed closing dyke or closure bund before
taking up construction of guide bund.
2503. APRON
Page 1211 of 1427

2503.1. General
This work shall consist of laying boulders

directly or in wire rates on the bed of rivers for
protection against scour.
Where the required size of boulders are not

available economically, concrete blocks of
equivalent weight shall be used. The grade of
concrete shall be M 15 nominal mix. (This holds
good for pitching on slopes and flooring also).
Cement concrete blocks shall be preferred here
practicable.
The stones used in apron shall be sound,

hard, durable and fairly regular in shape. Stone
subject to marked deterioration by water shall not
be used.
Quarry stones are preferable to round

boulders as the latter roll off easily. Angular stones
fit into each other better and have good interlocking
characteristics.
Where the required size stones are not

economically available, cement concrete blocks in
MIS grade conforming to Section 1700 or stones in
wire crates in combination may be used in place of
isolated stones of equivalent weight Cement concrete
blocks will be preferred, wherever practicable.
Page 1212 of 1427

2503.2. Laying Boulder Apron
The size of stone should conform to clause

5.3.7.2 of IRC:89.
The size of stone shall be as large as possible.

In no case any fragment shall weigh less than 40 kg.
The specific gravity of stones shall be as high as
possible and it shall not be less than 2.65.
To ensure regular and orderly disposition of

the full intended quantity of stone in the apron,
template cross walls in dry masonry shall be built
about a metre thick and to the full height of the
specified thickness of the apron at intervals of 30
metres all along the length and width of the apron.
Within these walls, the stone then shall be hand
packed.
The surface on which the apron is to be laid

shall be levelled and prepared for the length and
width as shown on the drawings. In case the surface
on which apron is to be laid is below the low water
level, the ground level may be raised upto low water
level by dumping earth and the apron laid thereon.
The quantity of stone required in the apron shall be
re-worked out by taking the toe of pitching at higher
level.
2503.3. Laying Wire Crates and

Mattresses in the Apron
Page 1213 of 1427

Wire crates shall be made from hot dipped
galvanized mild steel wire of diameter not less than
4 mm in annealed condition having tensile strength
of 300-450 MPa conforming to IS:280. The
galvanizing coating shall be heavy coating for soft
condition conforming to 15:4826.
The mesh of the crate shall not be more than

150 mm.
Wire crates for shallow or accessible

situations shall be 3 metre x 1.5 metre x 1.25 metre
in size. Where these have to be deposited and there
is a chance of overturning, the crate shall be divided
into 1.5 metre compartments by cross netting.
For deep or inaccessible situations, wire

crates can be made smaller subject to the approval of
the Engineer.
Wire crates built in-situ, shall not be larger

than 7.5 metres x 3. metres x 0.6 metre, nor smaller
than 2 metres x 1 metre x 0.3 metre. Sides of large
crates shall be securely stayed at intervals of not
more than 1.50 metres to prevent bulging.
The netting shall be made by fixing a row of

spikes on a beam at a spacing equal to the mesh. The
beam must be a little longer than the width of netting
required. The wire is to be cut to lengths about three
times the length of the net required. Each piece shall
be bent at the middle around one of the spikes and
Page 1214 of 1427

the weaving commenced from one corner.
A double twist shall be given at each

intersection. This twisting shall be carefully done by
means of a strong iron bar, five and half turns being
given to the bar at each splice.
The bottom and two ends of the crate or

mattress shall be made at one time. The other two
sides shall be made separately and shall be secured
to the bottom and the ends by twisting adjacent wires
together. The top shall be made separately and shall
be fixed in the same manner as the sides after the
crates or mattress have been filled.
Wherever possible, crates shall be placed in

position before filling with boulders. The crates shall
be filled by carefully hand-packing the boulders as
lightly as possible and not by merely throwing in
stones or boulders.
For laying of wire crates in aprons of bridges,

two situations arise:
(i) Where the crates are to be laid in deep

water and have to be dumped and then
joined together.
(ii) Where depth of water is low or dry bed ii
available. In such cases, the crates can be
laid at site.
2504. PITCHING / REVETMENT ON SLOPES
Page 1215 of 1427

2504.1. Description
This work shall consist of covering the slopes

of guide bunds, training works and road
embankments with stone, boulders, cement concrete
blocks or stones in wire crates over a layer of
granular material called filter. While river side
slopes are given this protection against river action,
the rear slopes, not subjected to direct attack of the
river, may be protected against ordinary wave
splashing by 0.3-0.6 metre thick cover of clayey or
silty earth and turfed.
2504.2. Pitching/Filter media
2504.2.1. Pitching : The pitching shall be

provided as indicated in the drawings. The
thickness and the shape of stone pitching shall be
shown on the drawing.
The stone shall be sound, hard, durable and

fairly regular in shape. Quarry stone should be used.
Round boulders shall not be allowed. The stones
subject to marked deterioration by water or weather
shall not be accepted.
The size and weight of stone shall conform to

clause 5.3.5.1 of IRC:89. No stone, weighing less
than 40 kg shall, however, be used. The sizes of
spalls shall be a minimum of 25 mm and shall be
suitable to fill the voids in the pitching.
Page 1216 of 1427

Where the required size stones are not
economically available, cement concrete blocks in
M15 grade conforming to Section 1700 or stones in
wire crates may be used in place of isolated stones of
equivalent weight. Cement concrete blocks will be
preferred wherever practicable. Use of geosynthetics
has been dealt with in Section 700.
2504.2.2. Filter media : The material for the

filter shall consist of sand, gravel, stone or coarse
sand. To prevent escape of the embankment material
through the voids of the stone pitching / cement
concrete blocks as well as to allow free movement of
water without creating any uplift head on the
pitching, one or more layers of graded materials,
commonly known as a filter medium, shall be
provided underneath the pitching.
The gradation of the filter material shall

satisfy the following requirements :
Provision of a suitably designed filter is

necessary under the slope pitching, to prevent the
escape of underlying embankment material through
the voids of stone pitching/cement concrete blocks
when subjected to the attack of flowing water and
wave action, etc. In order to achieve this
requirement, the filter may be provided in one or
more layers satisfying the following criteria :
Page 1217 of 1427

D 15 (Filter)
5
D 85 (Base)
D 15 (Filter)
4  20
D 15 (Base)
D 50 (Filter)
 25
D 50 (Base)
Notes:
(i) Filler design may not be required if

embankment consists of CH or Ch soils
with liquid limit greater than 30, resistant
to surface erosion. In this case, if a layer
of material is used as bedding for
pitching, it shall be well graded and its D
85 size shall be «t least twice the
maximum void size in pitching.
(ii) In the foregoing, D 15 means the size of
that sieve which allows 15 per cent by
weight of the filter material to pass
through it and similar is the meaning of
D 50 and D 85.
(iii) If more than one filter layer is
required, the same requirement as above
shall be followed for each layer. The
finer filter shall be considered as base
material for selection of coarser filter.
(iv) The filler shall be compacted to a
firm condition. The thickness of filler is
Page 1218 of 1427

generally of the order of 200 mm to 300
mm. Where filler is provided in two
layers, thickness of each layer shall be
150 mm.

2504.4.
Before laying the pitching, the sides of banks
shall be trimmed to the required slope and profiles
put up by means of line and pegs at intervals of 3
metres to ensure regular straight work and a uniform
slope throughout. Depressions shall be filled and
thoroughly compacted.
The filler granular material shall be laid over

the prepared base and suitably compacted to the
thickness specified on the drawings.
The lowest course of pitching shall be started

from the toe wall and built up in courses upwards.
The toe wall shall be in dry rubble masonry
(uncoursed) conforming to Clause 1405.3, in case of
dry rubble pitching and shall be in nominal mix
cement concrete (M 15) conforming to Clause
1704.3 in case of cement concrete block pitching.
The stone pitching shall commence in a

trench below the toe of the slope. Stone shall be
placed by derrick or by hand to the required length,
thickness and depth conforming to the drawings.
Stones shall be set normal to the slope, and placed so
that the largest dimension is perpendicular to the
Page 1219 of 1427

face of the slope, unless such dimension is greater
than the specified thickness of pitching.
The largest stones shall be placed in the

bottom courses and for use as headers for
subsequence courses.
In hand placed pitching, the stone of flat

stratified nature should be placed with the principal
bedding plane normal to the slope. The pattern of
laying shall be such that the joints are broken and
voids are minimum by packing with spalls,
wherever necessary, and the top surface is as smooth
as possible.
When full depth of pitching can be formed

with a single stone, the stones shall be laid breaking
joints and all interstices between adjacent stones
shall be filled in with spalls of the proper size and
wedged in with hammers to ensure tight packing.
When two or more layers of stones must be

laid to obtain the design thickness of pitching, dry
masonry shall be used and stones shall be well
bonded. To ensure regular and orderly disposition of
the full intended quantity of stone as shown,
template cross walls in dry masonry shall be built
about a metre wide and to the full height of the
specified thickness at suitable intervals and all along
the length and width of the pitching. Within these
walls the stones shall be hand packed as specified.
Page 1220 of 1427

2504.4. Toe Protection
In conformity with clause 5.3.7. of IRC:89, a

toe wall shall be provided at the junction of slope
pitching and launching apron of a guide bund so as
to protect the slope pitching from falling even when
the apron is not laid at low water level. The toe wall
shall be in dry rubble masonry {uncoursed)
conforming to Clause 1405.3 in case of dry rubble
pitching or pitching/ revetment with stones in wire
crates and in nominal mix cement concrete (M 15)
conforming to Clause 1704.3 in case cement
concrete blocks have been used in pitching. For
protection of toes of bank slopes terminating cither
in short aprons at bed levels or anchored in flooring /
rocky bed, the provisions of clause 8.2.2 of IRC:89
may be complied with. The relevant specifications of
the protective works for individual components will
be followed.
2505. RUBBLE STONE/CEMENT

CONCRETE BLOCK FLOORING OVER
CEMENT CONCRETE BEDDING

constructing rubble stone / c.c. block flooring laid
over a cement concrete (M 15) bedding. The floor
protection will comprise rigid flooring stated above
with curtain walls and flexible apron.
Page 1221 of 1427

Excavations for laying the bedding and floor
protection works shall be carried out as per
specifications under proper supervision. Before
laying the foundation and protection walls, the
excavated trenches shall be thoroughly inspected by
the Engineer-in-Charge to ensure that :
a) There are no loose pockets and unfilled

depressions left in the trench.
b) The soil at the founding level is properly
compacted to true lines and level so as to
have an even bedding.
c) All concrete and other elements arc laid
in dry bed.
Cement concrete nominal mix (grade M 15)

of 300 mm thickness shall then be laid in accordance
with provisions given in Section 1700 except that the
surface of the concrete shall not be given a smooth
finish. The paving work shall be embedded in green
concrete.
Flooring shall consist of 150 mm thick flat

stone/cement concrete blocks (Nominal mix Grade
M 15 conforming to Section 1700). It shall be
bedded on a layer of cement mortar (1:3) prepared to
Clause 1304. Spalls shall be used to fill in the voids.
The joints shall then be filled with cement mortar
and finished neat. The stone shall break joints and
the joints shall not exceed 20 mm in thickness.
Spacing of joints may be 20 m or so. The top of
flooring shall be kept to 300 mm below the Lowest
Page 1222 of 1427

bed level.
2506. DRY RUBBLE FLOORING
This work shall consist of constructing dry

rubble flooring at cross drainage works for relatively
less important works.
The base for the flooring shall be prepared to

the specified levels and slopes and compacted
suitably with hand rammers or other .means to have
an even bedding.
The thickness of flooring shall be made with

one stone only. The stones shall then be laid closely
on the prepared base in one or more layers as
specified and the bond used shall be as specified by
the Engineer.
2507. CURTAIN WALL AND FLEXIBLE

APRON
2507.1. Curtain Wall
The rigid flooring shall be enclosed by

curtain walls (tied to the wing walls) with a
minimum depth below floor level of 2 m on
upstream side and 2.5 m on downstream side. The
curtain wall will be in cement concrete M 15/stone
masonry in cement mortar 1:3. The rigid flooring
shall be continued over the top width of curtain wall.
Page 1223 of 1427

2507.2. Flexible Apron
Flexible apron 1 m thick comprising loose

stone boulders (weighing not less than 40 kg) shall
be provided beyond curtain walls for a minimum
distance of 3 m on upstream side and 6 m .on
downstream side. The work of floor protection shall
be simultaneously completed along with the work on
bridge foundations.

ACCEPTANCE


The protection works shall be measured as

set forth below. If directed by the Engineer for
measurement, the materials may have to be stacked
at site before laying and nothing extra will be paid
to the Contractor for this stacking.
The earth work in construction of

embankment for guide bund shall be measured in
cubic metres unless otherwise specified.
Page 1224 of 1427

The boulders/cement concrete blocks and
wire crates in apron shall be measured in cubic
metres.
The filter and stone pitching shall be

measured separately in cubic metres unless
otherwise specified.
Rubble stone/cement concrete blocks,

flooring and cement concrete bedding shall be
measured in cubic metres for each class of material.
Preparation of base for laying the flooring shall be
deemed incidental to the work.
For laying apron, excavation upto an average

depth of 150 mm shall be deemed to be included in
the main item and shall not be measured separately
unless otherwise specified. Excavation more than
150 mm shall be measured in cubic metres as given
in Clause 304.
2510. RATE
The contract unit rate for the construction of

embankment for guide bund shall cover the cost of
all materials including transportation, laying,
compacting, all labour, tools, equipment, sampling
and testing, supervision and all incidentals necessary
for completing the work according to these
specifications.
Page 1225 of 1427

The contract unit rate for one cubic metre of
finished work of a;-:on shall include the cost of all
material, labour, tools and plant for completing the
work according to above specifications. Excavation
upto an average depth of 150 mm shall also be
deemed to be included in the rate as dressing of the
bed. Excavation beyond this depth shall be paid
for separately unless otherwise specified.
The contract unit rate for one cubic metre of

filter or stone/cement concrete block pitching on
slopes shall include the cost of preparing the bases,
putting to the profiles, laying and compacting the
filter and stone pitching of dry rubble/cement
concrete block rivetment for embankment slopes to
the specified thickness, lines, curves, slopes and
levels and all labour and materials as well as tools
and plant required for the work.
The contract unit rate for rubble stone/cement

concrete block flooring shall include the cost of all
material, labour and tools and plant for completing
the work as per these specifications.
Page 1226 of 1427

Expansion Joints
2600
Expansion Joints
Page 1227 of 1427

2601. DESCRIPTION
This work shall consist of fabrication and

placing of expansion joints as indicated on the
drawing and conforming to these specifications or as
2602. GENERAL
a) The expansion joints shall be designed

and duly got approved by the Engineer.
It shall cater for expected
movement and rotation of the structure
at the joints and provide smooth riding
surface. It shall also be easy for
inspection, maintenance and
replacement.
b) Expansion joints shall be robust,
durable, water-tight and replaceable.
Site fabricated expansion joints shall be
prohibited. Expansion joints shall be
obtained by the Engineer either
directly or through the Contractor
from approved manufacturers and be of
proven type.
c) For bridges with prestressed concrete
superstructure,. with individual span
length more than 20 m or built with
innovative design/construction
elastomeric expansion joints of slab seal
or strip seal type shall be provided.
d) For slab type of bridges of spans less
Page 1228 of 1427

than 10 metres continuous surfacing
may be provided across the expansion
gaps, supported on a 20 mm thick plate
placed and fixed at the level of the deck
slab.
e) For bridges other than those mentioned
in (c) above with spans above 10 metres,
an alternative specification of sliding
steel plate joint or filled joints with
copper plates may also be adopted if
approved by the Engineer, apart from
elastomeric expansion joint of slab seal
or strip seal type.
f) Vehicular traffic shall not be allowed
over expansion joints after its
construction for such period as may be
determined by the Engineer.
g) Proprietary type deck joints offered by
the Contractor in lieu of the type
specified shall comply in all respects
with the manufacturer’s specifications
and meet the required range of
movements and rotations and be fit for
the purpose of ensuring satisfactory long
term performance in the bridge.
Where alternative type proprietary deck

joints are proposed by the Contractor, the following
information shall be provided.
(i) Name and location of the proposed

manufacturer.
Page 1229 of 1427

(ii) Dimensions and general details of the
joint including material specifications,
holding down bolt or anchorage details
and installation procedures.
(iii) Evidence of satisfactory performance
under similar environmental conditions
of similar joints being produced by the
manufacturer.
Any acceptance of alternative types will be at

the sole discretion of the Engineer.
Such deck joints shall be installed in

accordance with the manufacturer’s
recommendations and to the general requirements of
this Specification.
No expansion joint shall be provided only for

the width of the, carriageway. It shall follow the
profile including the kerb and the footway and facia,
if provided. The type of expansion joint for the latter
may be made different from that used for the
carriageway expansion joint
2603. REQUIREMENTS
2603.1. The requirement criterion will be

separately applicable for the expansion joint proper
and the transition zone of attachment to the deck.
2603.2. There are two types of performance
requirements for the expansion joint proper viz. from
the necessity of the bridge and from the road users
Page 1230 of 1427

e.g. man, animal and vehicle.
2603.3. Performance Requirement with Respect

to Bridges
The expansion joint shall :

a) Withstand the imposed load including
the impact load from live load and
other sources.
b) Allow expansion and contraction
movement due to temperature, creep,
shrinkage, prestressing and structural
deformations.
c) Permit relative rotation in elevation
and plan due to the causes as noted
above,
d) Be waterproof. Bridge deck expansion
joint seals play a critical role in
preventing the degradation of the
structural components of the bridge
system. Without effective joint seals,
water passes through the bridge deck
and works harmfully to corrode steel
components find cause deterioration of
the concrete. Ram water gathers
various corroding additives from
the atmosphere and also from the
carriageway.
e) Ensure sealing. In case bridge deck
joints are not sealed, apart from loss
of waterproofing, grit and other forms
of road debris may enter the joint
Page 1231 of 1427

Debris, when impacted with the joint
can seriously restrict the movement
instead of facilitating the same. In
the case of proprietary joints being
accepted for adoption, the sealing
shall be as specified by them,
f) Ensure long life by being resistant to
corrosion,
g) Be easy to install,
h) Be easy to maintain. Replaceability of
expansion joint shall be one of the
basic criteria for selection of type of
expansion .joint,
i) Be resistant to the materials likely to
collect/spill over the deck in its
normal service.
2603.4. Performance Requirement with Respect

to User
The expansion joint shall :
a) Provide smooth continuity at the top of

the deck for riding comfort,
b) Be of skid resistant surface,
c) Be non-damaging to the rubber tyre,
d) Make minimum noise during vehicular
crossing,
e) Ensure that animal paws and hooves
should not get entangled where bridges
are used by animal drawn traffic,
f) Permit passing of bullock cart steel tyre
Page 1232 of 1427

for bridges where bullock carts ply.
g) Look good aesthetically.
2603.5. Performance Requirement for Transition

Zone
It is the zone of connection of joint assembly

and the adjoining deck. The expansion joint shall :
a) Permit transfer of generated forces

without distress, i.e., without getting
uprooted. The purpose will not be
served if the bonding is with the
wearing coat only. Anchorage must be
provided with the deck structural
element,
b) Ensure that surface in the transition
zone stays undisturbed during long term
service.
2604. STEEL PLATE SLIDING EXPANSION

JOINTS
a) In this type of buried

joint, the wearing coat
shall be made
continuous over the
joint. The other
alternative shall be to
keep a gap in the
wearing coat which is
filled up with a seal
Page 1233 of 1427

and filler, to be
provided in extremely
hot areas.
b) Materials for steel
plates shall conform
to Section 1900. The
exposed metallic
components shall be
galvanised or coated
with approved anti-
corrosive paint The
thickness shall be 20
mm or so for
obtaining satisfactory
performance.
c) Plates shall be placed
to the line, grade and
expansion gap shown
on the drawings with
any adjustment
required for
temperature,
particular care being
taken with the top of
the plates.
d) Plates shall be
firmly held in place
during concreting by
methods approved by
the Engineer.
e) Any temporary bolts
or other fixings which
Page 1234 of 1427

prevent relative
movement of the
adjacent parts of the
joint shall be removed
as soon as the
concrete has set
sufficiently to hold
the expansion plates
in their correct
positions. In any
case., temporary
bolts or other fittings
shall be removed
within 6 hours of
placing concrete
unless otherwise
directed by the
Engineer.
f) Care shall be taken
to prevent damage to
expansion joint plates
or its coating.
g) If any damage occurs,
the plates and
coatings shall be
restored by the
Contractor to the
satisfaction of the
Engineer.
h) Plates shall be free of
oil, fast, loose paint or
other similar material
Page 1235 of 1427

before coating.
2605. FILLER JOINTS
a) The components of
this type of joint shall
be at least 2 mm thick
corrugated copper
plate placed slightly
below the wearing
coat, 20 mm thick
compressible fibre
board to protect the
edges, 20 mm thick
pre-moulded joint
filter filling the gap
upto the top level of
the wearing coat,
sealed with a joint
sealing compound.
b) The material used for
filling expansion joint
shall be bitumen
impregnated felt,
elastomer or any
other suitable
material, as specified
on the drawings.
Impregnated, felt
shall conform to the
requirements of IS:
1838, and shall be got
Page 1236 of 1427

approved from the
Engineer. The joint
filler shall consist of
Urge pieces and
assembly of small
pieces to make up the
required size shall be
avoided.
c) Expansion joint
materials shall be
handled with care
and stored under
cover by the
Contractor to prevent
damage.
d) Any damage
occurring after
delivery shall be
made good to the
satisfaction of the
Engineer and at the
expense of the
Contractor.
e) Joint gaps shall be
constructed as shown
on the drawings.
Surfaces joint grooves
shall be thoroughly
cleaned with a wire
brush to remove all
loose materials and
dirt and debris, then
Page 1237 of 1427

washed or jetted out.
f) Pre-moulded
expansion joint filler
shall not be placed in
position until
immediately prior to
the placing of the
abutting material. If
the two adjacent
surfaces of the joint
are to be placed at
different times, this
type of joint filler
shall not be placed
until the second face
is about to be placed.
g) Sealants shall be
installed in
accordance with the
manufacturer’s
recommendations and
all appropriate
requirements for joint
face priming.
h) Sealants snail be
finished
approximately 3 mm
below the upper
surfaces of the joint
i) Joint materials spilt or
splashed onto finished
surfaces of the bridge
Page 1238 of 1427

during joint filling
operations shall be
removed and the
surfaces made good
to the Engineer’s
approval.
j) No joint shall be
sealed until inspected
by the Engineer and
approval is given to
proceed with the
work.
2606. ELASTOMER1C SLAB SEAL

EXPANSION JOINT 2606.1. Materials
a) Steel inserts shall conform to IS:226.

Use of any other materials like fibre-
glass or similar material shall not be
permitted.
b) Elastomer for elastomeric slab unit
(ESU) shall conform to clause 91 S.I
of IRC:83 (Pan II), compounded to give
hardness 1RHD 60 ±5, subject to the
following additional stipulations :
i) Chloroprene (CR) only shall be
used in the manufacture of
elastomeric expansion joints. No
reclaimed/natural rubber or
vulcanized wastes shall be used.
ii) The chloroprene material used in
the manufacture of elastomeric
Page 1239 of 1427

(expansion joints) shall be
Neoprene WRT, Bayprene 110.
Skyprene B5 or Denka S-40V.
iii) Chloroprene content of the
compound shall not be lower than
60 per cent by weight The ash
content shall not exceed 5 pr cent
(as per tests conducted in
accordance with ASTM D-297 for
(i) and (ii) above.
iv) EP.DM and other similar
candidate elastomers for
expansion joints shall not be
permitted.
c) Elastomeric plugs.
d) Spacer ‘bars, marked with centre to
centre distance of fixing holes.
e) Fixing bolls and nuts made of stainless
steel.
f) Anchor bars comprising hooked anchor
stiffeners welded with lower steel
inserts and sinusoidal anchor bars
welded with horizontal leg of the edge
steel inserts. The elaborate anchoring
arrangements of steel inserts shall be
permanently welded/ tied with the steel
reinforcement
2606.2. Fabrication
a) Steel inserts shall be grit blasted

and provided with epoxy paint
Page 1240 of 1427

b) Edges of reinforcing steel sections
shall be rounded.
c) Expansion joints shall be fully
moulded to the required size in one
single vulcanising operation including
the encasing layers as integral and
homogeneous part
d) Tolerances of fabrication shall be as
follows :
i) Plan dimension -> ± 5 mm
ii) Total height -> ± 3 mm
2606.3. Supply and Handling
i) The Contractor shall supply all steel-

reinforced elastomeric expansion joints
including bolts, nuts, sealant, plugs and
all other accessories for the effective
installation of the joints including angled
jointing sections for kerbs.
ii) Expansion joint material shell be handled
with care and stored under cover by the
Contractor to prevent damage. Any
damage occurring after delivery shall be
made good at the expense of the
Contractor to the satisfaction of the
Engineer.
2606.4.1. Expansion joints shall be installed

as per approved drawing. Steel inserts, spacer bars,
Page 1241 of 1427

concreting of pockets, fixing of elastomer slab unit
and presetting, etc., shall be done as per the
following:
a) Steel Inserts
i) Deck casting shall be done
leaving pockets or recess for steel
inserts and anchors of the expansion
joint as per drawing.
ii) Steel inserts shall be lowered at the
appropriate location inside the
pocket.
iii) The top of the insert shall be flush
with the finished level of wearing
course maintaining the camber.
iv) Spacer bars, duly set appropriately
to the month of installation, shall
be fitted under proper supervision.
v) Anchor rods shall be tied/welded
with the cutting deck main
reinforcement, maintaining level
and alignment.
vi) Welding between anchor rods and
deck reinforcement is preferable. If
welding is not possible, strong steel
tie wires shall be used .for
fastening, under proper supervision.
b) Spacer Bar
i) Spacer bars shall be used to ensure
proper positioning of bolts and also
levelling of the steel inserts during
Page 1242 of 1427

fixing of the same with the deck
reinforcement and casting second
stage concreting in the pocket
thereafter.
ii) The 2nd stage concreting operation
shall preferably be started within 24
hours of fixing the steel inserts. In
such cases, spacer bars should be
removed just after concreting is
finished. If there is a substantial
time lag between fixing of inserts
and concreting, then any one of the
following methods shall be adopted,
depending on the support condition
:
a) For simply supported bridge
resting on simple elastomeric
bearings, (with no dowel
pins), insert shall be placed
in position with spacer bars
at every alternate joints. Such
joints shall be called
restrained joints hereafter. In
other words, inserts shall not
be fixed simultaneously at two
ends of one span. If the above
condition is satisfied, inserts
with spacer bars shall be
kept in position for a
substantially longer period at
such restrained joints. Spacer
bars shall be removed after
Page 1243 of 1427

concreting of such restrained
joints and inserts placed in
position with spacer bars at
the other unrestrained joints
thereafter.
b) For bridges resting on other
than elastomeric bearings
(including bearings with
dowel pin; al one end), after
placing and aligning the
inserts and securing the
same, the spacer bars stall be
removed Concreting shall be
done with great care so
that inserts are not
dislocated or distorted.
iii) While removing the spacer bar
after concreting, one must take care
to see that the concrete is not
damaged daring withdrawal of
spacer bar. If the spacer bar happens
to be snugly filled, it shall not be
pulled by any means; it shall be gas
cut in two pieces and then removed.
c) Concreting of Pocket
i) Concreting of pocket shall be done
with great care using proper mix
conforming to grade similar to that
of the deck casting besides ensuring
efficient bonding between deck and
steel insert. Also proper care shall
Page 1244 of 1427

be given for ensuring efficient
bonding with the already cast
concrete.
ii) Needle vibrators shall be used. Care
shall be taken so that the position of
steel insert is not disturbed during
vibration.
iii) Spacer bar shall be removed within
an appropriate time before the joint
is required to permit movement.
d) Fixing of Elastomeric Slab Unit

(ESU)
i) Special jig shall be used to
preset the ESU during installation
ii) ESU (mourned an the jig. if
preset) shall be lowered to
position.
iii) The line and level on the ESU
should be adjusted.
iv) ESU shall be removed and
coated with special adhesive
v) ESU shall be placed in
position again, ensuring waterproof
joining at required faces.
vi) ESU shall be tightened with
stainless steel nuts and lock washers
in position. Tightened nuts shall be
locked with lock washers.
vii) Special sealant shall be poured
inside the plug holes.
viii) The elastomeric plugs shall be
Page 1245 of 1427

pressed in .position after applying
adhesive on the appropriate surface.
ix) ESU shall be fitted in position after
completion of wearing course.
While completing this pan of the
wearing course, adequate care shall
be taken to ensure a waterproof,
joining with the already existing
wearing course.
e) Pre-Setting
i) The main purpose of presetting of
the steel inserts at the time of its
installation is to ensure as closely
as possible the condition that in
the long run at the mean average
annual temperature, the ESU
remains at its nominal state.
ii) Major factors responsible for
changing the longitudinal length of
the bridge superstructure are
indicated below :
a) Temperature variation from
annual mean.
b) Changes due to shrinkage of
concrete.
c) Changes due to elastic
shortening and creep of the
prestressed bridge
superstructure.
d) Deformation of superstructure
and substructure, if any.
Page 1246 of 1427

Resultant changes in expansion
gap due to first factor can occur in
both directions from any pre-
selected mean position whereas
changes due to creep and shrinkage
are unidirectional such that die
expansion gap continuously
increases with passage of lime.
The steel insert unit of expansion joint can be

fixed in any month of the year. As stated earlier, the
expansion gap between bridge superstructure may
vary from time to time; hence the initial fixing
distance between fixing points will obviously depend
on the month of installation of steel insert. The c/c
distance between stainless steel fixing of bolts as
indicated in the drawing can be taken as only
nominal. The same shall be modified by presetting
depending on :
(i) The difference between the mean

temperature of the month of fixing
of steel insert and the annual average
temperature.
(ii) The elapsed period between the
casting and/or prestressing and
fixing of steel insert for calculating the
remnant creep and shrinkage.
2606.4.2 Special requirements for installation
Page 1247 of 1427

i) Prior to construction of bridge deck area
adjacent to the joint, the supplier shall
provide detailed working drawings
“Showing the location of all bolts,
recesses and holes necessary for the
installation of the joint. Reinforcing bars
in superstructure shall be amended as
required to ensure that there will be no
interference in the installation of the
joint.
ii) All bearing surfaces and recesses which
are in contact with the joint assembly
shall be checked with a straight edge to
ensure flatness of profile.
iii) No holes shall be drilled for fixing bolts
within 7 days of concreting. Holes for the
bolts shall be drilled to the size and depth
iv) Sections of the jointing making the
completed joint shall follow a straight
line.
v) The fixing bolt* shall not be placed in a
position until at least 4 weeks after
stressing is completed in post-tensioned
box or beam and slab structures. Prior to
placing sections of jointing, contact
surfaces shall be cleaned to remove all
grease, tar, paint, oil, mud or any other
foreign material that may affect adhesion
of the sealant.
vi) Sealant shall only be applied to dry
contact surfaces. Sufficient sealant shall
Page 1248 of 1427

be applied 10 the contact surfaces to
cause extrusion of sealant when the
jointing is fixed in position.
vii) Final sealing of the finished expansion
joint shall be completed immediately
after completion of installation. All
exposed ends, joints between units and
other areas of possible leakage shall be
filled with sealant. All voids between the
sides of the jointing and concrete or
plates shall be filled with sealant.
viii) Bolt cavities shall be cleaned and plugged
with neoprene cavity plugs. Prior to
placing the plugs sufficient sealant shall
be placed in the cavities to cause
extrusion of the sealant by the plugs.
ix) All excess sealant shall be removed
from the jointing and adjacent areas.
2606.5. Acceptance Test
2606.5.1. As per clause 918.7 of IRC-83

(Part II), necessary quality control certification by
the manufacturer in regard to properties of Elastomer
and steel will be furnished.
For severe environment, ozone resistance test

as per clause 915.2.3 of IRC:83 (Part II), shall be
carried out for elastomer.
The properties of’ the elastomer shall

conform to Table 1 of clause 915.2 of IRC:83 (Part
Page 1249 of 1427

II). The acceptance testing for elastomer material
shall conform to clause 918.4.1.2 of IRC:83 (Part II)
with additional criteria as stated in Clause 2005.
2606.5.2. The fabricated expansion joint shall

be subjected to the following acceptance tests :
i) Routine test. Each expansion joint shall

be tested for at least 100 cycles for a test
movement which shall be 10 per cent
more than the design expansion/
contraction movement.
ii) In addition to routine test, one out of
every 20 expansion joints shall be
subjected to the test movement for 4000
cycles.
The lot shall be rejected if the elastomer

material shows signs of fatigue or
permanent set or distress in the test The
test piece shall not be used in ‘die bridge.
iii) The type test for abrasion resistance shall
be carried out for one joint out of every
20 nos. as per 15:3400 (Part 3) and the
standard deviation shall be within ± 20
per cent
N.B. The manufacturer shall preferably have

in-house testing facility. Otherwise, the testing shall
be got done by him at his expense at any testing
establishment selected by the Engineer. A
manufacturer who cannot carry out the acceptance
Page 1250 of 1427

test shall not be entitled to supply elastomeric slab
seal joint
2607. STRIP SEAL EXPANSION JOINT
2607.1. Components
Strip seal expansion joint shall comprise the

following items :
i) Edge beams - This special claw leg
profiled member shall be of extruded
rolled steel section combining good
weldability with notch toughness.
ii) Strip seal - This shall be of chloroprene
with high tear strength, insensitive to
oil, gasoline, and ozone. It shall have
high resistance to aging. This component,
provided to ensure water tightness, shall
have bulbous shape of the pan of the seal
which is inserted into the groove,
provided in the edge beam. The seal
should be vulcanised in single operation
for minimum full length of joint.
iii) Rigid Anchorage - This shall be welded
to the edge beam at staggered distance.
iv) Anchor loops - This shall be made of
weldable steel connecting the rigid
anchorage with, deck reinforcement
2607.2. Material
Page 1251 of 1427

a) Edge beams of this special section are
at present being directly imported in
India. The steel shall conform to steel
grade Rst 37-2 of German Standard or
equivalent.
b) Chloroprene of strip seal shall conform to
clause 915.1 of RC:83 (Pan II). The
properties of chloroprene shall conform
to Table 2600-1
c) Anchorage steel shall conform to IS:2061
d) Anchor loop shall conform to 13:2062.
TABLE 2600-1. STRIP SEAL ELEMENT

SPECIFICATION
Scaling element is made of chloroprene and

must be a extruded section. The working movement
range of the sealing element shall be at least 80 nun
with a maximum of 100 mm at right angles to the
joint and ±40 mm parallel to the joint
PROPERTY SPECIFIED
VALUE
Hardness 63±5 Shore A
Tensile Strength Min 11 MPa
Elongation at fracture Min 350 per cent
Tear Propagation
Strength Mm 10 N/mm
Page 1252 of 1427

Longitudinal Min 10 N/mm
Transverse Min 25 per cent
Shock Elasticity Min 220 mm3
Abrasion
Residual Compressive Max 28 per cent

Strain
(22 h/70 deg C/30 per
cent strain) Max +5 Shore A
Max -20 per cent
Ageing in hot air Max -20 per cent
(14 days/70 deg C)
Change in hardness
Change in tensile No cracks
strength
Change in elongation at
fracture
Ageing in ozone
(24 h/50pphm/25 deg Max 5 per cent
C/20 per cent strain) Max 10 Shore A
Swelling behaviour in Max 25 per cent

Oil Max 20 Shore A
(116 h/25 per cent Q Min -35 deg C
ASTM Oil no.
Volume Change
Change in hardness
ASTM Oil no.3
Volume Change
Change in hardness
Cold Hardening Point
Page 1253 of 1427

26073. Fabrication (Pre-installation)
a) Rolled steel profiles for edge beams

shall be long enough to cater for a 2-
lane carriageway. These shall be cut to
size of actual requirements by meant
of a metre box saw. Alignment of the
cut-to-size steel profiles shall then be
made in accordance with the actual
bridge cross-section on work tablet. For
this purpose, the contour of bridge
cross-section shall be sketched onto
these tables. After the steel profiles are
aligned, they will be chucked to the
tables by means of screw clamps and
tacked by arc welding.
b) Anchor plates shall be cut to the
required size by gat cutting. These
shall be welded to the edge beams.
c) Anchor loops shall be bent to the
required shape and welded to anchor
plates.
d) The finally assembled joints shall then
be clamped and transported to the work
site.
2607.4. Handling and Storage
a) For transportation and storage, auxiliary

brackets shall be provided to hold the
Page 1254 of 1427

joint assembly together.
b) The manufacturer shall supply
either directly to the Engineer . or to
the Bridge Contractor all the materials
of strip seal joints including sealants
and all other accessories for the
effective installation of the jointing.
c) Expansion joint material shall be
handled with care. It shall be stored
under cover on suitable lumber padding
by the Contractor to prevent damage.
Any damage occurring after delivery
shall be made good at the Bridge
Contractor’s expense to the
2607.5.1. The width of the gap to cater for

movement due to thermal effect, prestress,
shrinkage and creep, superstructure deformations
(if any) and sub-structure deformations (if any) shall
be determined and intimated to the manufacturer.
Depending upon the temperature at which the joint is
likely to be installed, the gap dimension shall be
preset.
2607.5.2. Taking the width of gap for

movement of the joint into account, the dimensions
of the recess in the decking shall be established in
accordance with the drawings or design data of the
manufacturer. The surfaces of the recess shall be
Page 1255 of 1427

thoroughly cleaned and all din and debris
removed. The exposed reinforcement shall be
suitably adjusted to permit unobstructed lowering
of the joint into the recess.
2607.5.3. The recess shall be shuttered in

such a way that dimensions in the joint drawing are
maintained. The formwork shall be tight.
2607.5.4. Immediately prior to placing the

joint, the presetting shall be inspected. Should the
actual temperature of the structure be different from
the temperature provided for presetting, correction of
the presetting shall be done. After adjustment, the
brackets shall be tightened again.
2607.5.5. The joint shall be lowered in a pre-

determined position. Following placement, of the
joint in the prepared recess, the joint shall be
levelled and finally aligned and the anchor loops on
one side of the joint welded to the exposed
reinforcement bars of the structure. Upon
completion, the same procedure shall be followed for
the other side of the joint. With the expansion joint
finally held at both sides, the auxiliary brackets shall
be released, allowing the joint to take up the
movement of the structure.
2607.5.6. High quality concrete shall then be

filled into the recess. The packing concrete must
feature low shrinkage and have the same strength as
that of the superstructure, but in any case not less
Page 1256 of 1427

than M 35 grade. Good compaction and careful
curing of concrete is particularly important. After die
concrete has cured, the movable installation brackets
still in place shall be removed.
2607.5.7. Rolled up neoprene strip seal shall

be cut into the required length and inserted between
the edge beams by using a crow bar pushing the bulb
of the seal into the steel grooves of the edge beams.
A landing to a bead shall be formed in the thickened
end of the edges of the sea! which would force the
thickened end against the steel beam due to wedge
effect when the strip seal is buttoned in place.
2607.5.8. As soon as the concrete in the

recess has become initially set, a sturdy ramp shall
be placed over the joint to protect the exposed steel
beams and neoprene seals from site traffic.
Expansion joint shall not be exposed to traffic
loading before the carriageway surfacing is placed.
2607.5.9. The carriageway surfacing shall be

finished flush with the top of the steel sections. The
actual junction of the surfacing/wearing coat with
the steel edge section shall be formed by a wedge
shaped joint with a sealing compound. The
horizontal leg of the edge beam shall be cleaned
beforehand. It is particularly important to ensure
thorough and careful compaction of the surfacing
in order to prevent any premature depression
forming in it.
Page 1257 of 1427

Acceptance Test
(i) All steel elements shell be finished with
conform corrosion protection system.
(ii) For neoprene seat, the acceptance test
shall conform to the requirement!
stipulated in Table 2600-1. It shall also be
stretch tested. If a manufacturer is to
supply this type of joint, they will have to
produce a test certificate accordingly
conducted in a recognised laboratory, in
India or abroad.
(iii) In view of the importance of the built up
edge beam*, special investigation of
fatigue strength of this section with
anchorages to withstand 2x10* load
change cycles without showing signs of
damage, will be required. The supplier
shall have to produce a test certificate in
this regard, conducted in a recognised
laboratory, in India or abroad.
(iv) The manufacturer shall produce test
certificates indicating that anchorage
system had been tested in a recognised
laboratory to determine optimum
configuration of anchorage assembly
under dynamic bating.
(v) The manufacturer shall satisfy the
Engineer that water tightness test for the
type of joint has been carried out in a
recognised laboratory to check the water
tightness trader a water pressure of 4
bars.
Page 1258 of 1427

(vi) As strip seal type of joint if specialised in
nature generally of the proprietary type,
the manufacturer shall be required to
produce evidence of satisfactory
performance of this type of joint.

ACCEPTANCE



PAYMENT
The expansion joint shall be measured in

running metres. For filled joints, the rate per running
metre shall include the cost of sealant for the depth
provided in this drawing.
2610. RATE
The contract unit rate shall include the cost of

all material, labour, equipment and other incidental
charges for fixing the joints complete in all respects
as per these specifications in the case of Bridge
Contractor supplying the expansion joint. If the
Page 1259 of 1427

manufacturer supplies the expansion joint directly to
the Engineer, the cost of installation, handling and
fixing shall be borne by the Bridge Contractor.
Wearing Coat and Appurtenances

2700
Wearing Coat and
Appurtenances
Page 1260 of 1427

2701. DESCRIPTION
This work shall include wearing coat and

bridge appurtenances such as railing, approach slab,
drainage spouts, weep notes in conformity with
details shown on the drawing and these specifica-
tions or as approved by the Engineer.
2701 WEARING COAT
2702.1. Bituminous Wearing Coat
Specifications for bituminous

concrete/bitumen mastic in wearing coat shall
conform to Section 500 except for the special
requirements as stated hereinafter.
2702.1.1. Principles of bituminous wearing

coat shall comprise the following :
(i) A layer of mastic asphalt, 6 mm thick

after applying a prime coat over the top
of the deck before the wearing coat is
laid. The prime coat and the layer of
mastic asphalt shall be laid as per Clauses
503 and 51S respectively.
(ii) 50 mm thick asphaltic concrete wearing
coat in two layers of 25 mm each as per
Clause 512
in case of high rainfall intensity areas, the

thickness of mastic asphalt layer may be increased to
Page 1261 of 1427

12 mm.
2702.1.2. For high traffic density, an

alternative specification for wearing course
comprising 40 mm bituminous concrete overlaid
with 25 mm thick bitumen mastic layer can be
adopted. The work shall be done in conformity with
Section 500.
2702.2. Cement Concrete Wearing Coat
Cement concrete wearing coat may be

provided in case of isolated bridge construction or
bridges located in remote areas. It .shall not be laid
monolithic with the deck.
The thickness of wearing coat shall be 75

mm. The minimum grade of concrete shall be M 30
with water cement ratio as 0.4.
Curing of wearing coat earlier than what is

generally required may be resorted to, so as to avoid
formation of shrinkage cracks in hot weather.
All carriageway and footpath surfaces shall

have non-skid characteristics.
The cross slope in the deck shall be kept as

2.5 per cent for decks, level in longitudinal profile.
2702.3. For providing cross camber no

variation in thickness of coat shall be permitted.
Page 1262 of 1427

2703. RAILINGS
2703.1. General
a) Bridge railing includes the portion of

the structure erected on and above the
kerb for the protection of pedestrians
and traffic
b) Railings shall not be constructed
until the centering falsework for die
span has been released and die span is
self-supporting. For concrete with steel
reinforcement, specifications of the items
of controlled concrete and reinforcement
mentioned under relevant sections of this
specifications shall be applicable.
c) The type of railing shall be carefully
erected true to line and grade. Posts
shall be vertical with a tolerance not to
exceed 6 mm in 3 metres. The pockets
left for posts shall be filled up with
non-shrinkable mortar.
d) The type of railing to be constructed
shall be u shown on the drawings.
e) Care shall be exercised in assembling
expansion joints in the railings to ensure
that they function property.
f) The bridge railings shall be amenable to
quick repairs.
g) Railing materials, particularly metal
railings, shall be handled and stored with
Page 1263 of 1427

care, so that the material tad pans arc
kept clean and free from damage.
Railing materials shall be stored
above the ground on platforms, skids, or
other supports and kept free from
grease, din and other contaminants.
Any material which is lost, stolen or

damaged after delivery shall be replaced or repaired
by the Contractor. Methods of repair shall not
damage the material or protective coating.
2703.2. Metal Railings
Materials, fabrication, transportation,

erection and painting for bridge railings snail
conform to the requirements of section 1900.
All complete steel rail elements, pipe

terminal sections, posts, bolts, nuts, hardware and
other steel fittings shall be galvanised or painted
with an approved paint.
If galvanised, all elements of the railing shall

be free from abrasions, rough or sharp edges, and
shall not be kinked, twisted or bent If straightening is
necessary, it shall be done by methods approved by
the Engineer.
Damaged galvanised surfaces, edges of holes

and ends of steel railing cut after galvanising shall be
cleaned and re-galvanised.
Page 1264 of 1427

The railing shall be carefully adjusted prior
to fixing in place to ensure proper matching at
abutting joints and correct alignment and camber
throughout their length: Moles for field connections
shall be drilled with the railing in place in the
structure at proper grade and alignment.
Unless otherwise specified on the drawings,

metal railing shall be given one shop coat of paint
and three coats of paint after erection if sections are
not galvanised.
Railings shall not follow any irregularity in

the alignment of the deck. When shown on the
drawings, the rail elements shall be curved before
erection.
27033. Cast-in-Situ Concrete Railings
The portion of the railing or parapet which is

to be cast in place shall be constructed in accordance
with the requirements for Structural Concrete in
Section 1700. The reinforcement shall conform to
Section 1600.
Forms shall either be of single width boards

or shall be lined with suitable material duly approved
by the Engineer. Form joints in plane surfaces will
not be permitted.
All mouldings, panel work and bevel strips
Page 1265 of 1427

shall be constructed according to the details shown
on the drawings. All corners in the finished work
shall be true, sharp and clean-cut and shall be free
from cracks, spalls or other defects. Casting of posts
shall be done in single pour.
2703.4. Precast Concrete Railings
Precast members for railings shall be of

reinforced cement concrete and shall conform to the
specifications given in Sections 1600 and 1700. The
maximum size of the aggregate shall be limited to 12
mm and the concrete grade shall be M 30. The
precast members shall be removed from the moulds
as soon as practicable and shall be kept damp for a
period of at least 10 days. During this period they
shall be protected from sun and wind. Any precast
member that becomes chipped, marred or cracked
before or during the process of placing shall be
rejected. Special care shall be taken to watch the
surface of the cast-in-situ portion of the deck.
2704. APPROACH SLAB
Reinforced concrete approach slab covering

the entire width of the roadway shall be provided as
per details given or. the drawings or as approved by
the Engineer. Minimum length of approach slab shall
be 3.5 m and minimum thickness 300 mm.
The cement concrete and reinforcement shall
conform to Sections 1700 and 1600 respectively.
The base for the approach slab shall be as shown on
Page 1266 of 1427

the drawings or as directed by the Engineer.
2705. DRAINAGE SPOUTS
2705.1. This work shall consist of furnishing

and fixing in position of drainage spouts and
drainage pipes for bridge decks.
Drainage along longitudinal direction shall

be ensured by sufficient number of drainage fixtures
embedded in the deck slab. The spouts shall be of
not less than 100 mm in diameter and shall be of
corrosive resistant material such as galvanised steel
with suitable clean-out fixtures. The spacing of
drainage spouts shall not exceed 10 m. The
discharge from drainage spout shall be kept away
from the deck structure. In case of viaducts in urban
areas, the drainage spouts should be connected with
suitably located pipelines to discharge the surface
run-off to drains provided at ground level.
2705.2. Fabrication
The drainage assembly shall be fabricated to

the dimensions shown on the drawings; all materials
shall be corrosion resistant; steel components shall
be of mild steel conforming to 15:226. The drainage
assembly shall be seam welded for water tightness
and then hot-dip galvanised.
2705.3. Placement
Page 1267 of 1427

The galvanised assembly shall be given two
coats of bituminous painting before placement. The
whole assembly shall be placed in true position, lines
and levels as shown in the drawing with necessary
cut-out in the shuttering for deck slab and held in
place firmly. Where the reinforcements of the deck
are required to be cut, equivalent reinforcements
shall be placed at the corners of the assembly.
2705.4. Finishing
After setting of the deck slab concrete, the

shrinkage cracks around the assembly shall be totally
sealed with polysulphide sealant or bituminous
sealant as per IS: 1834 and the excess sealant
trimmed to receive the wearing coat After the
wearing coat is completed, similar sealant shall be
finished to cover at least SO mm on the wearing
coat surface all round the drainage assembly.
2706. WEEP HOLE
Weep holes shall be provided in solid plain

concrete/reinforced concrete, brick/stone masonry,
abutment, wing wall and return walls as shown .on
the drawing or directed by the Engineer to drive
moisture from the back filling. Weep holes shall be
provided with 100 mm dia AC pipe for structures in
plain/reinforced concrete or brick masonry. In case
of stone masonry, weep holes shall be 80 mm wide,
150 mm high or circular with 150mm diameter.
Weep holes shall extend through the full width of
Page 1268 of 1427

concrete/masonry with slope of about 1 vertical:20
horizontal towards the draining face. The spacing of
weep holes shall generally be 1m in either direction
or as shown in the drawing with the lowest at about
150 mm above the low water level or ground level
whichever is higher or as directed by the Engineer.

ACCEPTANCE


standards of acceptance
PAYMENT
The measurement for payment for wearing

coat, railings and approach slab shall be made as
given below :
(i) Cement concrete wearing coat shall he
measured in cubic metres. Asphaltic
concrete wearing coat shall be measured
in square metres.
(ii) Railings shall be measured in running
metres.
(iii) Approach slab and its base shall be
measured separately in cubic metres.
(iv) Drainage spouts shall be measured in
Page 1269 of 1427

numbers.
(v) Weep holes in concrete/brick masonry
structure shall be measured in numbers.
For structures in stone masonry, weep
holes shall be deemed to be included in
the item of stone masonry work and shall
not be measured separately.
2709. RATE
The contract unit rate for wearing coat shall

include the cost of all labour, material, tools and
plant and other cost necessary far completion of the
work as per these Specifications.
The contract unit rate of railings shall include

the cost of all labour material, tools and plant
required for completing the work as, per these
Specifications.
The contract unit rate for approach slab shall

plant required for completing the work as per these
Specifications. The rate for base shall include cost of
all labour, material, tools and plant required,
including preparation of surface and consolidation
complete .in all respects.
The contract unit rate for each drainage spout

shall include the cost of all labour, material, tools
and plant required for’ completing the work as per
these Specifications. It shall also include the cost of
Page 1270 of 1427

providing flow drain pipes with all fixtures upto the
point of ground drains wherever shown on the
drawings.
The contract unit rate for weep hole shall

plant required for completing the work as per these
Specifications.
Page 1271 of 1427

Repair of Structures
2800
Repair of Structures
Page 1272 of 1427

2801. DESCRIPTION
Repair of structures shall be carried out in

accordance with the repair -plans and these
Where ^repair work is not covered by these
specifications, special specification may be framed.
Implementation of repair schemes shall also

conform to provisions Of IRC:SP:40.
2802. GENERAL
2802.1. Environmental Aspect
Care shall be taken to ensure suitable

mitigation measures against noise and dust, pollution
and damages to the environs whether temporary or
permanent and shall be taken as incidental to work.
2802.2. Phasing
The sequence of work shall be in accordance

with the drawings or as directed by the Engineer.
2802.3. Traffic Management
Traffic management, signage, signalling

arrangement, barricading, and lighting arrangement
shall be in accordance with Section 100 and with
these specifications and shall be considered as
incidentals to work.
Page 1273 of 1427

2802.4. Safety Precautions
Adequate precautions shall be taken for

safety of personnel, road users and existing services,
which, during execution, shall be considered as
incidentals to work.
Persons working should wear safety helmets
and rubber gloves.
2802.5. Dismantling and Removal of

Material
Dismantling of any bridge component and

removal of materials shall conform to Section 200
and this section and as shown on the drawings or as
2803. SEALING OF CRACKS BY INJECTION

OF EPOXY RESIN
2803.1. General
The work of epoxy adhesive utilising the

Structural Concrete Bonding Process shall conform
to these specifications.
2803.2. The Contractor shall furnish detailed

methodology of construction including sources of
supply of material, tools, equipment and appliances
to be used on work, details of personnel and
supervision.
Page 1274 of 1427

2803.3. Personnel
The Contractor’s personnel shall be qualified

and experienced in epoxy injection process.
2803.4. Material
The material for injection shall be suitable

two-component low viscosity epoxy resin, having
the required characteristics of bonding with concrete
and resistance to moisture penetration. Epoxy mortar
or polysulphide resin may be used for sealing the
surface.
The material for epoxy injection shall

conform to the following :
(i) The .mixing ratio of resin and

hardener shall generally be between 1 to
1 and 2 to 1 by volume subject to
manufacturer’s recommendation.
(ii) Neither the mixed epoxy adhesives
nor their individual components shall
contain solvents and thinners.
(iii) The components shall be free of
lumps or foreign material. The viscosity
of the individual components shall not
change more than ±\5 per cent when kept
in closed containers al 25 degrees Celsius
after two .weeks.
(iv) Consistency requirement
Page 1275 of 1427

Standard Low
Version Viscosity
cps Version
cps
Viscosity of Mixed (200-300) (100-190)
Adhesive at 25 degrees
Celsius
v) Pot Life of 1 hour ± 15
mixed minutes*
adhesive at
25 degrees 3 - 6 hours
Celsius
vi) Set time of
mixed
adhesive at
25 degrees
Celsius
* In the case of two component injection

system where resin and hardener get mixed at point
of injection pot life at 25 degrees Celsius shall be not
greater than 15 min ±10 minutes.
2803.5. Equipment for Injection
The equipment shall be portable, positive

displacement type pumps with interlock to provide
positive ratio control of exact proportions of the two
components at nozzle. The pumps shall be generally
electrically powered and shall provide in-line
metering and mixing. The tolerance on mix ratio
shall be 5 per cent by volume. The injection
Page 1276 of 1427

equipment shall have automatic pressure control
capable of discharging mixed adhesive at any pre-set
pressure within the prescribed limits and shall be
additionally equipped with a manual pressure
control.
The injection equipment shall be equipped

with sensors on both the components A and B
reservoirs that will automatically stop the machine
when only one component is being pumped to the
mixing head.
If considered appropriate, suitable

compressed air operated epoxy injection gun can be
used with prior approval of the Engineer for manual
injection of mix when resin and hardener had been
mixed in a separate unit
2803.6. Preparation
Surfaces adjacent to cracks or other areas of

application shall be cleaned of dirt, dust, grease, oil
efflorescence or other foreign matter by
brushing/water jetting/sand blasting. Acids and
corrosives shall not be permitted for cleaning.
Entry ports shall be provided along the crack

at intervals of not more than the thickness of
concrete at the location.
Surface seal material shall be applied to the

face of the crack between the entry ports. For
Page 1277 of 1427

through cracks, surface seal shall be applied to both
faces.
Before proceeding with the injection, the

surface seal material must gain adequate strength
with respect to concrete strength of the member/
injection pressure.
2803.7. Epoxy Injection
Injection of epoxy adhesive shall begin at

lowest entry port and continue until there is an
appearance of epoxy adhesive at the next entry port
adjacent to the entry port being pumped.
When epoxy adhesive travel is indicated by

appearance at the next adjacent port, injection shall
be discontinued on the entry port being pumped and
entry port shall be sealed. Thereafter, epoxy
injection shall be transferred to next adjacent port
where epoxy adhesive has appeared.
Epoxy adhesive injection shall be performed

continuously until cracks are completely filled.
If port to port travel of epoxy adhesive is not

indicated, the work shall immediately be stopped. In
case the volume of the injected material exceeds 2
litres for a particular entry port, the work shall be
stopped and the specifications may be reviewed.
2803.8. Precautions for Application
Page 1278 of 1427

a) Unless otherwise specified, components
A and B, i.e., resin and hardener, shall
be at a temperature between 10 degrees
Celsius and 35 degrees Celsius at the
lime of mixing.
b) Temperature of structural member
during epoxy injection shall be
between 10 degrees Celsius and 35
degrees Celsius unless otherwise
specified.
c) Immediately prior to use, each
component shall be thoroughly mixed
with a clean paddle. The paddle shall be
of a type that does not induce air into
the material. Separate clean paddle must
be used for each component
d) Any heating of the adhesive components
shall be done by application of indirect
heat in case the work is to be done in
cold climate.
e) Just before use, the two components
shall be thoroughly mixed in the ratios
specified by the manufacturer. The length
of mixing time shall be in strict
accordance with manufacturer’s
recommendations. When mixed, all
adhesives with different coloured
components shall have a uniform colour
without streaks.
f) The use of solvents and thinners will
not be permitted except for cleaning of
Page 1279 of 1427

equipment
2803.9. Testing
2803.9.1. Material Testing : Prior to

approval of the material, the following tests shall be
carried out at site or in an authorised laboratory for
each batch of resin and hardener and each
combination thereof at the cost of the Contractor.
(i) Viscosity lest for resin and hardener

and the mix - three specimens each,
(ii) Pot life test - three specimens each,
(iii) Bond lest - three specimens each.
(iv) Shear test - six specimens each, 3 after
24 hours and the other three after 72
hours of curing
Subsequent tests shall be carried out as

a) Pot Life Tests

i) 500 gm of resin formulation shall
be prepared by thoroughly mixing
the resin and
hardener/accelerator/catalyst
component in proposed
proportion in a 1 kg capacity
hemisphere) porcelain bowl by
means of a spatula or any other
agitating device and note down
the time and the ambient
Page 1280 of 1427

temperature.
ii) With a clean dry 25 mm size
painter’s brush, the resin
formulation shall be applied on a
clean dry surface such as cement
concrete over 15-20 cm length,
starting immediately after mixing
the formulation and repeating
operation every five minutes.
When it becomes just difficult to
spread the resin properly with the
brush, the time is noted. The time
elapsed since completion of
mixing of resin formulation is
taken as its pot life.
iii) One pot life test shall be
performed on commencement of
work and the same shall be
repeated every four hours.
iv) In case the material fails to satisfy
the pot life test it shall not be
used for injection.
Where the resin and hardener get

mixed at point of injection, the
pot life is not important and no
tests may be required.
b) Bond Test
A standard ISO mm diameter and 300

mm long concrete cylinder shall be cast
Page 1281 of 1427

in 2 pieces by providing a separating
media at an axis of 45 degrees Celsius
10 the longer axis of the cylinder (refer
to Fig. 2800/1).
Three sets of such split cylinders shall

be prepared in advance. Two pieces of
each set shall be joined with epoxy
mortar at four points to give a clear gap
of about 0.2 mm, which will be injected
with epoxy resin at site. After epoxy has
been cured, load test is carried out on the
cylinder which shall not be less than 80
per cent of the cube strength of the
concrete mix and the failure shall not
take place at the joint injected with
epoxy resin.
c) Shear Tests
Two steel plates, minimum 3mm thick,

shall be bonded with epoxy at site using
the same resin mix as used/proposed lo
be used for injection. The assembly
shall be kept in mechanical clamp till
epoxy is cured. A total of six specimens
shall be prepared for each batch of
materials. Three test specimens shall
then be subjected to a shear force along
the axis after 24 hours and the
minimum shear strength before failure
shall not be less than 1 MPa. (refer Fig.
Page 1282 of 1427

2800/2).
The remaining test specimens shall be

similarly tested after 72 hours of curing. The shear
strength before failure shall not be less than 2.5
MPa.
2803.9.2. Core test : If directed by the

Engineer, core tests shall be conducted for the
acceptance of the work. The selection of the location
of cores shall be made under the direction of the
Engineer in such a way that damage in
critical/stressed areas of the structure is avoided. The
procedure for the lest shall be as under.
The Contractor shall obtain 5 cm diameter

initial core samples in the first 50 linear metres.
Thereafter, frequency of core sampling shall be as
specified or as agreed by the Engineer,
The depth of the core shall generally be less

than 20 cm. Tests and Acceptance Criteria shall be
as follows :
a) Penetration/Visual Examination - a
minimum of 90 per cent of the crack shall
be full of epoxy adhesive.
b) Bond Strength : Concrete failure before
adhesive failure or 40 MPa with no
failure of either concrete or adhesive
If the cores taken in first 50 m length pass
Page 1283 of 1427

tests as specified above, epoxy adhesive injection
work at area represented by cores will be accepted.
If cores fail either by lack of penetration or

bond strength, work shall not proceed further until
the areas represented by the cores are re-injected and
retested for acceptance.
Filling of Field Control Testing Core Holes
This procedure consists of using two-

component bonding agent applied to surfaces of
cored holes followed by application of Non-Shrink
cement grout mix placed by hand trowel, thoroughly
rodded and tamped in place, and finished to match
finish and texture of existing concrete to the
satisfaction of the Engineer. Materials and
procedures for filling testing core holes shall be
submitted to and approved by the Engineer before
proceeding with core testing work.
Page 1284 of 1427

Page 1285 of 1427
2803.9.3. Test for injection equipment : At
all times during the course of the work the
Contractor shall keep complete and accurate records
and make available to the Engineer of the pressure
and ratio tests specified above so that the efficacy
and accuracy of the injection equipment is verified
In addition, the Engineer at any time without

prior intimation of the Contractor may request the
Contractor to conduct the tests specified below, in
the presence of the Engineer.
a) Pressure Test
The mixing head of the injection

equipment shall be disconnected and the
two adhesive component delivery lines
shall be attached to the pressure check
device, which shall consist of two
independent valved nozzles capable of
sensing the pressure. The check device
shall be closed and equipment operated
until the gauge pressure in each line reads
5 MPa. The pumps shall be stopped and
the gauge pressure shall not drop below 4
MPa within 2 minutes.
The pressure test shall be run for each

injection unit at the beginning arid after
break of every shift
b) Ratio Test
Page 1286 of 1427

The mixing head of the injection
equipment shall be disconnected and the
two adhesive components shall be
pumped simultaneously through the ratio
check device, which shall consist of two
independent valved nozzles. There shall
be a pressure gauge capable of
controlling back pressure by opening or
closing valved nozzles capable of sensing
the back pressure behind each valve. The
discharge pressure shall be adjusted to
read 5 bar for both adhesive components
which shall be simultaneously discharged
into separate calibrated containers during
the same lime period and the amounts
discharged into the calibrated containers
simultaneously during the same period
shall be compared to determine that the
volume/discharge conforms to the
manufacturer’s recommended ratio for
applicable material.
2804. EPOXY MORTAR FOR

REPLACEMENT OF SPALLED CONCRETE
2804.1. Material
2804.1.1. Formulation
The epoxy resins for use in the mortar shall
Page 1287 of 1427

be obtained from a reputed manufacturer and the
mortar shall be prepared in conformity with the
manufacturer’s recommendations.
They shall generally conform to the

following:
Pot Life : 90 minutes at 25

degrees Celsius
: 60 minutes at 30
degrees Celsius
: 45 minutes at 35
degrees Celsius
Bond Strength : 12 MPa
Tensile Strength : 16 MPa
The Contractor shall carry out tests on the

samples made out or requirements indicated above.
The sand content in the mortar shall be in

accordance with the desired consistency.
2804.2. Proportioning and Mixing
The resin and hardener shall be mixed before

adding the dry filler. The mixed ready to use mortar
should not contain lumps of unwetted filler and
should be uniform in colour. For a total weight of 1
kg or less, hand mixing will be sufficient. For
quantities in excess of 1 kg, the component shall be
mixed for 3 minutes with a slow speed - 400-600
rpm - electric drill with a Jiffy mixer. The stirrer
Page 1288 of 1427

shall be moved up and down and along the sides
until an even streak free colour is obtained.
Whipping in an excessive amount of air shall be
avoided. If no power is available, a fiat putty knife
may be used to roach into the comers of the can and
hand mixing done for at least 5 minutes.
2804.3. Surface Preparation
Surface upon which epoxy is to be placed

shall be free of rust.
All emptied, used buckets, rags and

containers shall be removed. from site. These shall
be stored in waste disposal bags and suitably
disposed.
2805. ETOXY BONDING OF NEW

CONCRETE TO OLD CONCRETE
2805.1. Epoxy resin used for bonding shall

be obtained from a reputed manufacturer. The pot
life of such bonding epoxy shall not be less than 60-
90 minutes at normal temperature.
2805.2. The entire surface of the existing

concrete member should be thoroughly cleaned by
wire brush and then with compressed air to remove
dust and loose particles from the surface. Any crack
or spalling of concrete shall be sealed by epoxy
injection/epoxy mortar/grouting as decided by the
Engineer. A coating of suitable epoxy resin at the
Page 1289 of 1427

rate of 0.8 kg/sq.m. (minimum) should then be
applied on the surface of the existing concrete
members.. Fresh concrete shall then be placed within
the pot life of the resin system.
2805.3. Testing
2805 3.1 Epoxy used for bonding work shall

satisfy the criteria mentioned in Clause 2803.9.
2805.3.2. Two concrete cubes 150 mm size

cast as per approved design mix shall be placed, as
shown in Fig. 2800/3 at a distance of ISO mm from
each other. Epoxy resin system suggested for
bonding new to old concrete shall be applied on the
opposite faces of the cubes.
Fresh cement concrete cube of grade as per

approved design mix shall be cast with water cement
ratio of 0.4 or less in the manner shown in Fig.
2800/3. The assembly shall be cured in water for 28
days and steel spacer removed thereafter.
The cube assembly shall .be subjected to

compression load after 28 days of curing, thereby
subjecting the bond to shearing load. Failure must
not occur at this joint
2806. CEMENT GROUTING 2806.1.

Material
Grouting shall normally be performed with a
Page 1290 of 1427

mixture of neat Portland Cement and water. Other
additives and admixtures may be added to improve
the impermeability, strength, etc. on the approval of
the Engineer. The size of the particles and the
consistency of the grout must be suited to the
passageways it must follow. Neat grout will not flow
freely into holes smaller than about three times the
largest cement particle. Except in large cavities
where thick mortar can be placed, the sand should all
pass the 28-mesh sieve and have a large portion
passing the 50- and the 100- mesh sieves. The
proportions of Ordinary Portland Cement to sand
will depend upon the size of the spaces to be filled
and will vary from a neat grout to about 1:1 mix. The
amount of water to be added depends upon the
consistency required. Grouts with as little as 16 litres
of water per bag of cement could be handled and it
should seldom be necessary to use more than 35 to
40 litres of water per bag of cement.
Where necessary and approved by the

Engineer, admixtures to Portland Cement grout
mixtures may be added for delaying the setting time,
increasing flow ability, minimising segregation and
shrinkage.
Page 1291 of 1427

Page 1292 of 1427
2806.2. Preparation
The surface shall be cleaned with wire brush

and compressed air. IS mm dia and ISO to 200 mm
deep holes along the length of the cracks at a spacing
of 500 mm may be drilled by wet drilling using
rotary percussion drills and nipples, inserted in these
holes.
2806.3. Proportioning, Mixing, and

Equipment for Grouting
The cement grout shall be mechanically

mixed using a system of power-driven paddles of
high speed centrifugal pump. The grout pump to be
used shall permit close control of pressures to allow
a flexible rate of injection with minimum clogging of
valves and ports. The most satisfactory equipment
for injecting grout is a pump of the double-acting
flexible reciprocating type giving a steady flow. The
grout pump shall be. so placed as to reduce the waste
in cleaning lines. It is preferable to add 50 per cent
or more of the mixing water into the mixer before
adding the dry ingredients and then the remaining
water. A continuous supply of grout is preferable to
an intermittent one. Consistency of the grout may be
determined by trials starting with thin grout i.e.
about 40 litres of water per bag of cement and
progressively decreasing the water content to about
IS litres per bag of cement.
Where the mixer and pump are combined in
Page 1293 of 1427

one unit, the dry material shall be screened before
mixing. If the mixer and pump are in separate units,
the grout shall pass through a screen before it enters
the pump.
2806.4 Application
Highest practical pressure within the limits

100-400 kPa should be used in order to force the
surplus water from the grout. As the pressure may be
distributed hydraulically over considerable areas,
vigilance must be exercised to prevent damage or the
needless waste of grout Grouting is to be done by
attaching a packer (consisting of expansible tube of
rubber) to the end of the grout supply pump through
the holes and nipples.
Pressure shall be steady to ensure a

continuous flow of grout. Grouting shall not be
continued till the hole consumes mix at the rate of
not less than 30 litres in 20 minutes or until refusal at
the grouting pressure of 400 kPa at any hole until
refusal. Should the grout escape from an adjacent
nipple, it should be plugged or capped. Any seam,
crack or joint through which grout escapes shall be
caulked with epoxy mortar as soon as thick grout
appears.
2806.5. Cleaning of Equipment
After completion of each grouting operation

or temporary shutdown, it is advisable to force clear
Page 1294 of 1427

water through the pump until the discharge line
shows no colour, after which the pump covers shall
be removed and the valve chambers thoroughly
cleaned.
2806.6. Testing
Percolation test done at the. end of grouting

operation shall give a value of less than 2 lugions.
NOTE : For specialised treatment like polymer

modified cementitious grout injection,
manufacturer’s literature and
specification shall be followed.
2807. GUNITING/SHOTCRETE
2807.1. The gunite is a mixture of cement,

sand and water. It comprises 100 parts by weight of
cement, 300 parts by weight quartz sand, 35-50 parts
by weight water and 2 parts by weight approved
quick setting compound. In general, dry mix
shotcrete shall be used.
2807.2. Ordinary Portland cement

conforming to IS:269 shall be used in guniting.
2807.3. Sand for guniting shall comply with

the requirements stipulated in IS:383. In general,
sand should neither be too coarse to increase the
rebound nor too fine to increase the slump. Sand
should preferably have a moisture content between 3
Page 1295 of 1427

to 6 per cent.
The grading of sand shall lie within the

limits given below
IS Sieve Designation per cent Passing the sieve
4.75 mm 95 - 100
2.36 num 65 - 90
1.18 mm 45 -75
600 microns 30 - 50
300 microns 10 - 22
150 microns 2-8
2807.4. For thick sections it may be

advantageous to incorporate coarse aggregate in the
mix provided adequate guniting equipment is
available. Coarse aggregate, when used, shall
conform to grading given in Table I of IS:9012. The
percentage of coarse aggregate may normally be
kept as 20 to 40 per cent of the total aggregate and
the mix shall be suitably designed.
2807.5. Water/cement ratio for guniting shall

fall within the range 0.35 to 0.50 by mass, wet
enough to reduce the rebound. Drying shrinkage
may be between 0.06 per cent to 0.10 per cent The
quick setting compound shall be added at the nozzle
with water just before guniting.
2807.6. Workmanship
Page 1296 of 1427

The cement and sand shall be batched and
mixed and conveyed through a hose pipe with the
help of compressed air. A separate line shall bring
the water under pressure. The cement, sand and
water mix shall be passed through and intimately
mixed in a special ‘manifold and then projected at
high velocity to the surface being repaired. The
density of gunite shall not be less than 2000 kg/cu-
m. The strength of gunite shall not be less than 25
MPa. For effective guniting, the nozzle shall be kept
60 to 150 cm away from the surface, preferably
normal to that surface. While enclosing
reinforcement bars during repairs the nozzle shall be
held closer at a slight angle and the mix shall be
wetter than the normal.
2807.7. Test panels simulating actual field

conditions shall be fabricated for conducting
preconstruction testing. The procedure for testing
the cubes or cylinders taken from the panels
stipulated in clause 6 of 18:9012 shall be followed.
2807.8. It should be ensured from tests that

a strength of about 25 MPa at 28 days is available
for the mortar/concrete mix.
2807.9. The defective concrete shall be cut

out to the full depth till sound concrete surface is
reached. Under no circumstances should the
thickness of concrete to be removed be less than
clear cover to the main reinforcement. No square
shoulders shall be left at the perimeter of the cut-off
Page 1297 of 1427

portion and all edges shall be tapered. Thereafter, all
loose and foreign materials should be removed and
the surface be sandblasted to make it rough to
receive shotcrete after applying a coat of bonding
epoxy as per recommendation of the manufacturer @
1.0 kg per 1.5 sq.m. of surface area.
2807.10. The exposed reinforcement shall

be thoroughly cleaned free of rust, scales etc. by
wire brushing. Wherever the reinforcements have
been corroded, the same shall be removed and
replaced by additional reinforcement. Before
application of gunite, a coat of neat cement slurry
should be applied on the surface of the
reinforcement.
2807.11. Sufficient clearance shall be

provided around the reinforcement to permit
encasement with sound gunite. Care shall be taken to
avoid sand pockets behind the reinforcement.
2807.12. A thickness of 25 to 40 mm of
gunite can normally be deposited in one operation.
If, for some reason, the total thickness is to be built
up in successive operations, the previous layer
should be allowed to set bat not become hard
before the application of the subsequent layer. It
would always be necessary to apply guniting .or. a
damp concrete surface.
2807.13. Where required, welded wire

fabrics 5cm x 5 cm x No. 10 gauge shall be
Page 1298 of 1427

provided in the first layer of guniting. The fabric
shall be tied properly. In case the damage to the
concrete member is too deep, the specifications for
guniting as well as requirement of placement of
wire mesh has to be decided as per field
conditions.
2807.14. The stipulations given in IS:9012

regarding application of gunite should be followed
so as to keep the rebound to the minimum. The
quality of guniting and workmanship shall be
such that the percentage of rebound mentioned in
IS:9012 can be adhered to. In no circumstances
shall the rebound material be re-used in the work.
2807.15. It would be desirable that green

gunite is moistened for at least 7 days. Guniting
work shall not be done during windy or rainy
conditions.
2808.
REPLACEMENT/RECTIFICATION OF
BEARINGS
2808.1. The replacement/rectification of
bearings shall be carried out in accordance .with
approved repair plan or as approved by the Engineer.
2808.2. Lifting of superstructure spans may

be carried out by jacking up from below or by
lifting the span from top. Where jacks are
employed, their location/number and size shall
be selected in such a manner % that there are no
Page 1299 of 1427

undue stresses created in the structure. Jacks may
be placed on piers/pier caps or specially erected
trestles in accordance with the approved
methodology for lifting of superstructure. All jacks
shall be operated from one control panel by a
single control lever. The system will have
provision for manual over ride to control the
loads of any particular jack. The jacks should
be so synchronised that differential lift between
individual jacks shall not exceed 1 mm
2808.3. Necessary repair/replacement of

bearings shall be carried out as indicated in the
repair plan or as directed by the Engineer. Care shall
be taken to plan the execution of repair in the
shortest possible period.
2808.4. Precautions during Lifting of

Girders for Rectification of Bearings
Walkie talkies system or similar audio
arrangements should be available for communicating
instructions regarding lifting, stopping, starting etc.
The operator shall have a clear view of the jacks and
the lifting of each girder controlled by reading the
dial gauges.
2809. DISMANTLING OF CONCRETE

WEARING COAT
2809.1. Commencement of Dismantling
(i) Before commencing dismantling, the
Page 1300 of 1427

nature and condition of concrete, the
condition and position of reinforcement
should be ascertained. The Contractor
shall familiarise himself with the
structural design and ensure that the
overall stability of the bridge is not
affected.
(ii) The existing expansion joint assemblies
shall be removed carefully along the
entire width of the carriageway. The
deck slab for a width of 400 mm on
either side should be removed for
placing of reinforcement, anchor rods,
anchor bolts and other fixing
assemblies for the new expansion joints
and pouring of fresh concrete. The gap
between the girders over the piers
should be cleared of all debris. A
temporary platform in the gap at the
end of girders shall be erected to collect
the materials falling down during
concreting and fixing of expansion
joints
(iii) The service lines, if any, shall be
disconnected/ diverted before the
dismantling work starts.
2809.2. Dismantling of concrete wearing

coat shall be carried out using jack hammers or
suitable manual methods as .approved by the
Engineer. Care should be taken to avoid any damage
to the existing structure including reinforcement or
Page 1301 of 1427

prestressing anchorages for cables, if any, located in
the deck slab.
2809.3. Precautions During Dismantling

Work
For general guidelines, reference may be

made to Section 100.
Dismantling work shall not be carried out at

night, or during storm or heavy rain. A warning
device shall be installed in the area to be used to
warn the workers in case of mishap/emergency.
Safety helmets conforming to IS:2925 shall

be used by the workmen engaged in dismantling
work. The sheds and tool boxes should be located
away from the work site. Goggles preferably made
up of celluloids and gas masks shall be worn at the
time of dismantling, especially where tools like jack
hammers are deployed to protect eyes from injuries
from flying pieces, din, dust etc. Leather or rubber
gloves shall be worn by the workers during the
demolition of RCC work. Screens made up of GI
sheets shall be placed wherever necessary to prevent
the flying pieces from injuring the workers.
Water should be sprayed to reduce the dust

while removing concrete wearing course with jack
hammer. No work shall be taken up under the span
when dismantling work is in progress.
Page 1302 of 1427

2810. EXTERNAL PRESTRESSEMG
2810.1. Various components constituting

the system of external prestressing are as follows :
H.T. Strands/Wires, HDPE Sheathing,

Deviator Blocks, Anchor Plates, Anchorages and
grouting material.
2810.2. Material
H.T. Strands / Wires :
H.T. Strands wires shall conform to Section

1000.
HDPE Sheathing :
HDPE Sheathing shall conform to IS:4984

suitable for a working pressure of 6 bars. Its density
shall be 955 kg/cum, shore hardness D63, yield
stress 24 MPa and ultimate tensile strength 35 MPa.
Deviator Blocks :
As necessitated by the profile of the external

cable, suitable strand/ wire deviator block fabricated
from M.S.Sections shall be provided. The deviator
block shall be given a coat of suitable paint
(preferably epoxy based) after sand blasting.
Anchorages :
Page 1303 of 1427

Depending upon the prestressing force,
suitable anchorages and \vedges shall be used
conforming to relevant codes and section 1800.
2810.3. Workmanship
a. Stressing of cables shall be carried out

u per instructions given in the drawing,
and conforming to Section 1800.
b. Care should be taken to avoid any
damage to the existing structure by way
of stress concentration or any other
reason daring fixing of the deviator
blocks and after stressing of cable. The
deviator blocks shall be so fixed as not
to allow any movement due to
prestressing forces. Radius of
curvature of the surface of the deviator
block interfacing with the cable shall be
minimum one metre.
c. The anchorages shall be sealed with
suitable epoxy mortar system after the
stressing of cables. A minimum cover
of 50mm shall be provided for the
anchor plates and anchorages.
d. Suitable grouting inlet points and vent
points shall be provided by way of
HDPE “T” vent connections to the
sheathing.
e. Grouting of cables shall be carried out
as per provisions made in Section 1800.
Page 1304 of 1427

2810.4. It shall be ensued that no pan of the
existing structure is damaged/distressed due to the
external prestressing.
The behaviour of the girder shall be

monitored by measurement of deflection so that only
required amount of external prestressing is imparted
to the girder. Care shall be taken to avoid excess
prestressing and impairment to the girders.

ACCEPTANCE


Specifications and shall meet die prescribed
a) Measurement for sealing of cracks and

injection shall be made by weight of
epoxy consumed in kg for epoxy
grouting. For provision of nipples
required for grouting, the payment shall
be for number of nipples inserted.
b) Measurement for sealing of cracks and
injection shall be made by weight of
Page 1305 of 1427

cement consumed in kg for cement
grouting.
c) Measurement for application of epoxy
mortar for specified thickness shall be
per square metre of surface area of
application.
d) Measurement for bonding of old and
new concrete by epoxy mortar shall
be measured in square metre surface
area of interface.
e) Measurement for guniting / shotcreting,
shall be per square metre of surface area
of application.
f) Payment for replacement/rectification of
bearings shall be for each number of
bearing assembly replaced/rectified.
g) Dismantling of wearing coat shall be
measured in square metre of area of
wearing course dismantled.
h) Provision of external prestressing shall be
measured in tonnes of H.T. steel
strand/wire measured from anchorage
to anchorage before stressing.
2813. RATE
The contract unit rate for sealing of cracks

and injection of cement grout shall include cost of all
materials, labour, tools and plant, placing in position,
testing, curing and other incidental expenses for the
satisfactory completion of the work as per these
specifications.
Page 1306 of 1427

The contract unit rate for application of
epoxy mortar for specified thickness shall include
cost of all materials, labour, tools and plant, placing
in position, testing and other incidental expenses
including surface preparation for the satisfactory
completion of the work as per these specifications
and as shown on the drawings.
The contract unit rate for guniting/shotcreting

shall include cost of all materials, labour tools and
plant, placing in position, testing, curing,- surface
preparation and other incidental expenses including
the provision of nipples for the satisfactory
completion of the work as per these specifications.
The contract unit rate for

replacement/rectification of bearings snail include,
cost of all materials, labour, tools and plant, placing
in position, site welding/riveting/bolt connections,
operation of jacks and other incidental expenses for
the satisfactory completion of the work as per these
specifications and as shown on the drawings.
The contract unit rate for dismantling of

wearing coat shall include cost of all materials,
labour, tools and plant, traffic management,
signages, safety precautions and other incidental
expenses including removal of existing expansion
joints for the satisfactory completion of the work as
per these specifications.
The contract unit rate for external
Page 1307 of 1427

prestressing shall include cost of all materials,
labour, tools and plant, temporary works, testing,
curing and other incidental expenses including the
careful monitoring of the deflection of girders being
externally prestressed for the satisfactory completion
of the work as per these specifications and as shown
on the drawings.
Page 1308 of 1427

Pipe Culverts
2900
Pipe Culverts
Page 1309 of 1427

2901. SCOPE

installing reinforced cement concrete pipes, of the
type, diameter and length required at the locations
shown on the drawings or as ordered by the Engineer
and in accordance with the requirements of these
Specifications.
2902. MATERIALS
All materials used in the construction of pipe

culverts shall conform to the requirements of Section
1000.
Each consignment of cement concrete pipes
shall be inspected, tested, if necessary, and approved
by the Engineer either at the place of manufacture or
at the site before their incorporation in the works.
2903. EXCAVATION FOR PIPE
The foundation bed for pipe culverts shall be

excavated true to the lines and grades shown on the
drawings or as directed by the Engineer. The pipes
shall be placed in shallow excavation of the natural
ground or in open Benches cut in existing
embankments, taken down to levels as shown on the
drawings. In case of high embankments where the
height of fill is more than three times the external
diameter of the pipe, the embankment shall first be
built to an elevation above the top of the pipe equal
to the external diameter of the pipe, and to width on
Page 1310 of 1427

each side of the pipe of not less than five times the
diameter of pipe, after which a trench shall be
excavated and the pipe shall be laid.
Where trenching is involved, its width on

either side of the pipe shall be a minimum of 150
mm or one-fourth of the diameter of the pipe
whichever is more and shall not be more than one-
third the diameter of the pipe. The sides of the trench
shall be as nearly vertical as possible.
The pipe shall be placed where the ground

for the foundation is reasonably firm. Installation of
pipes under existing bridges or culverts shall be
avoided as far as possible. When during excavation
the material encountered is soft, spongy or other
unstable soil, and unless other special construction
methods are called for on the drawings or in special
provisions, such unsuitable material shall be
removed to such depth, width and length as directed
by the Engineer. The excavation shall then be
backfilled with approved granular material which
shall be properly shaped and thoroughly compacted
upto the specified level.
Where bed-rock or boulder strata are

encountered, excavation shall be taken down to at
least 200 mm below the bottom level of the pipe
with prior permission of the Engineer and all
rock/boulders in this area be removed and the space
filled with approved earth, free from stone or
fragmented material, shaped to the requirements and
Page 1311 of 1427

thoroughly compacted to provide adequate support
for the pipe.
Trenches shall be kept free from water until

the pipes are installed and the joints have hardened.
2904. BEDDING FOR PIPE
The bedding surface shall provide a firm

foundation of uniform density throughout the length
of the culvert, shall conform to the specified levels
and grade, and shall be of one of the following two
types as specified on the drawings:
(i) First Class bedding: Under first class

bedding, the pipe shall be evenly
bedded on a continuous layer of well
compacted approved granular material,
shaped concentrically to fit the lower
pan of the pipe exterior for at least ten
per cent of its overall height or as
otherwise shown on the drawings. The
bedding material shall be well graded
sand or another granular material
passing 5.6 mm sieve suitably
compacted/rammed. The compacted
thickness of the bedding layer shall be
as shown on the drawings and in no
case shall it be less than 75 mm.
(ii) Concrete cradle bedding: When
indicated on the drawings or directed by
the Engineer, the. pipe shall be bedded
Page 1312 of 1427

in a cradle constructed of concrete
having a mix not leaner than M 15
conforming to Section 1700. The shape
and dimensions of the cradle shall be as
indicated on the drawings. The pipes
shall be laid on the concrete bedding
before the concrete has set.
2905. LAYING OF PIPE
No pipe shall be laid in position until the

foundation has been approved by the Engineer.
Where two or more pipes are to be laid adjacent to
each other, they shall be separated by a distance
equal to at least half the diameter of the pipe subject
to a minimum of 450 mm.
The arrangement for lifting, loading and

unloading concrete pipes from factory/yard and at
site shall be such that the pipes do not suffer any
undue structural strain, any damage due to fall or
impact. The arrangement may be got approved by
the Engineer.
Similarly, the arrangement for lowering the

pipe in the bed shall be got approved by the
Engineer. It may be with tripod-pulley arrangement
or simply by manual labour in a manner that the pipe
is placed in the proper position without damage.
The laying of pipes on the prepared

foundation shall start from the outlet and proceed
Page 1313 of 1427

towards the inlet and be completed to the specified
lines and grades. In case of use of pipes with bell-
mouth, the belled end shall face upstream. The pipes
shall be fitted and matched so that when laid in
work, they form a culvert with a smooth uniform
invert.
Any pipe found defective or damaged during

laying shall be removed at the cost of the Contractor.
2906. JOINTING
The pipes shall be jointed either by collar

joint or by flush joint In the former case, the collars
shall be of RCC 150 to 200 mm wide and having the
same strength as the pipes to be jointed. Caulking
space shall be between 13 and 20 mm according to
the diameter of the pipe. Caulking material shall be
slightly wet mix of cement and sand in the ratio of
1:2 rammed with caulking irons. Before caulking,
the collar shall be so placed that its centre coincides
with the joint and an even annular space is left
between the collar and the pipe.
Flush joint may be internal flush joint or

external flush joint In either case, the ends of the
pipes shall be specially shaped to form a self
centering joint with a jointing space 13 mm wide.
The jointing space-shall be filled with cement
mortar, 1 cement to 2 sand, mixed sufficiently dry to
remain in position when forced with a trowel or
rammer. Care shall be taken to fill all voids and
Page 1314 of 1427

excess mortar shall be removed.
For jointing pipe lines under light hydraulic

pressure, the recess at the end of the pipe shall be
filled with .jute braiding dipped in hot bitumen or
.other suitable approved compound. Pipes shall be so
jointed that the bitumen ring of one pipe shall set
into the recess of the next pipe. The ring shall be
thoroughly compressed by jacking or by any other
suitable method.
All joints shall be made with care so that

their interior surface is smooth and consistent with
the interior surface of the pipes. After finishing, the
joint shall be kept covered and damp for at least four
days.
2907. BACKFILLING
Trenches shall be backfilled immediately

after the pipes have been laid and the jointing
material has hardened. The backfill soil shall be
clean, free from boulders, large roots, excessive
amounts of sods or other vegetable matter, and
lumps and shall be approved by the Engineer.
Backfilling upto 300 mm above the top of the pipe
shall be carefully done and the soil thoroughly
rammed, tamped or vibrated in layers not exceeding
150 mm, particular care being taken to thoroughly
consolidate the materials under the haunches of the
pipe. Approved pneumatic or light mechanical
tamping equipment can be used.
Page 1315 of 1427

Filling of the trench shall be carried out
simultaneously on both sides of the pipe in such a
manner that unequal pressures do not occur.
In case of high embankment, after filling the

trench upto the top of the pipe in the above said
manner, a loose fill of a depth equal to external
diameter of the pipe shall be placed over the pipe
before further layers are added and compacted.
2908. HEADWALLS AND OTHER

ANCILLARY WORKS
Headwalls, wing walls, aprons and other

ancillary works shall be constructed in accordance
with the details shown on the drawings or as directed
by the Engineer. Masonry for the walls shall
conform to Section 1300,1400 or 1700 as applicable.
Aprons shall conform to Section 2500.
2909. OPENING TO TRAFFIC
No traffic shall be permitted to cross the pipe

line unless height of filling above the top of the pipe
line is at least 600 mm.
R.C.C. pipe culverts shall be measured along

their centre between the inlet and outlet ends in
linear metres.
Page 1316 of 1427

Selected granular material and cement
concrete for pipe bedding shall be measured as laid
in cubic metres. Ancillary works like headwalls, etc.,
shall be measured as provided for under the
respective Sections.
2911. RATE
The Contract unit rate for the pipes shall

include the cost of pipes including loading,
unloading, hauling, handling, storing, laying in
position and jointing complete and all incidental
costs to complete the work as per these
Specifications.
Ancillary works such as excavation including
backfilling, concrete and masonry shall be paid for
separately, as provided under the respective Clauses.
Page 1317 of 1427

Maintenance of Road
3000
Maintenance of Road
Page 1318 of 1427

3001. GENERAL
The Specifications shall apply to all items of

road maintenance works as required to be carried out
under the Contract or as directed by the Engineer.
The works shall be carried out in conform by with
the relevant Specifications to the required level,
grade and lines using approved materials. The works
shall be carried out using light duty machinery or
manual means provided the quality of the end
product does not suffer. In execution of maintenance
works, a reference is made to the IRC publications:
“Manual for Maintenance of Roads” and “Code of
Practice for Maintenance for Bituminous Surfaces of
Highways, IRC 82-1982” for guidance and
compliance wherever applicable. Wherever the
Specification is not clear, good engineering practice
shall be adopted in the construction to the
satisfaction of the Engineer. 3002. RESTORATION
OF RAW CUTS
3002.1. Scope
The work shall consist of earthwork for

restoration of rain cuts in the embankment and
shoulders, using suitable material, and compacting
the same.
3002.2. Materials
The material used for restoration of rain cuts

shall consist of soil conforming to Clause 3QS.2.
Page 1319 of 1427

3002.3. Construction Operation
The area affected by rain cuts shall be cleared

of all loose soil and benched. The width of the
benches shall be at least 300 mm and they shall
extend continuously for a sufficient length. The
height of the benches shall be in the range of 150-
300 mm.
Fresh material shall be deposited in layers

not exceeding 250 mm loose thickness and
compacted so as to match with the benching at a
moisture content close to the optimum. Compaction
shall be carried out using suitable equipment such as
plate compactors and rammers or by suitable
implements handled manually. The finished work
shall conform to alignment, levels and slopes as
indicated in the drawing.
The earthwork for restoration of rain cuts

shall be measured in cubic metres.
3002.5. Rate
The Contract rate for the item of earthwork

for restoration of rain cuts shall be payment in full
for carrying out the required operation including full
compensation for:
(i) Supply of material including all leads
Page 1320 of 1427

and lifts and the cost of arrangement of
land;
(ii) Setting out;
(iii) Removal of loose material from the rain
cuts;
(iv) Benching of old earthwork; and
(v) Compacting after adding required
quantity of water.
3003. MAINTENANCE OF EARTHEN

SHOULDER
3003.1. Scope
The work of maintenance of earthen shoulder

shall include making up the irregularities/loss of
material on shoulder to the design level by adding
fresh approved soil and compacting it with
appropriate equipments or to strip excess soil from
the shoulder surface as per the requirement of this
Specification.
3003 2. Material
The material to be added to the shoulder, if

required, shall be a select soil conforming to Clause
305.
3003.3. Construction Procedure
This work shall involve:

(i) Making up of the earthen shoulder by
Page 1321 of 1427

adding extra soil and compacting the
same; and, or
(ii) Stripping a layer of soil to achieve the
required grade and level.
Wherever extra earth is required to be added,

the earthen shoulder shall be stripped and loosened
to receive fresh soil. The deficiency of thickness
shall be made up in layers of loose thickness not
exceeding 250 mm. Water shall be added, if
required, to attain the optimum amount and the layer
compacted by 80 to 100 kN smooth wheel roller,
vibratory roller, hand roller, plate vibrator or hand
rammer to obtain at least 94 per cent of the
maximum dry density in accordance with IS : 2720
(Part 8). The finished surface shall have the specified
cross slope and line in accordance with the drawing.
The side slopes shall be trimmed to the required
slope with the help of grader or manual methods
using hand tools.
Wherever the earth is required to be

excavated from the shoulder, this shall be done
either using equipment like grader or by manual
means using hand tools. The resulting surface shall
be uniform and have a field density of at least 94 per
cent of maximum density obtained in accordance
with IS:2720 (Part 8). If the surface is not uniformly
compacted, it shall be excavated to a depth of 150
mm and the soil mixed with water if required and
compacted at a moisture content close to the
optimum to achieve 94 per cent of maximum density
Page 1322 of 1427

as stated above.
Maintenance of earthen shoulder shall be

measured in sq. metres.
3003.5. Rate
The Contract unit rate for maintenance of

earthen shoulder shall be payment in full
compensation for:
(i) furnishing earth required for making up

of shoulders including all leads and
lifts, cost of land and compaction;
(ii) excavation of earth as required and
disposal of the earth at the location
approved; and
(iii) all tools, equipments and incidentals to
complete the work in accordance with
the above Specification.
3004. BITUMINOUS WORK IN CONNECTION

WITH MAINTENANCE AND REPAIRS
3004.1. General
The scope and type of maintenance work to

be carried out shall be in accordance with the
provisions of the Contract or as instructed by the
Engineer.
Page 1323 of 1427

In all instances it will have been necessary to
identify the causes of defects in order to permit
effective repair. Where investigation work into the
causes of defects is included in the Contract it shall
be carried out in accordance with the appropriate
provisions of this Specification.
Maintenance treatments required under the

Contract or instructed by the Engineer may include
pothole and patch repair, crack-sealing, fog spray,
dusting, slurry sealing, surface dressing, overlays
and specialist repairs.
When the pavement to be maintained is

intended to carry volumes of traffic in excess of 1.5
million e.s.a. the constructed materials (particularly
patching and overlay materials) used in maintenance
operations shall be of a standard not less than those
specified for the original construction.
Traffic control during maintenance

operations shall conform to the requirements of the
Contract documents.
3004.2. Filling Pot-holes and Patch

Repairs
3004.2.1. Scope : This work shall include

repair of pot-holes and of all types of bituminous
pavement.
Page 1324 of 1427

The work shall include the removal of all
failed material, in the pavement courses and, if
necessary, below the pavement, until the root cause
of the failure is removed; the trimming of the
completed excavation o provide firm vertical faces;
the replacement of material of at least as high a
standard as that which was originally specified for
the pavement layer; the painting of tack coat on to
the sides and bases of excavations prior to placing of
any bituminous materials and the compaction,
trimming and finishing of the surfaces of all patches
to form a smooth continuous surface, level with the
surrounding road.
3004.2.2. Materials : All materials used for

the pot-hole and patch repair of bituminous surface
and underlying layers shall be in accordance with
this- Specification and shall be of the same type as
specified for the original construction. A mix
superior to the one on the existing surface may also
be used for repair work. An emulsified
bitumen/modified bitumen mix compatible with the
existing layer shall also be considered appropriate.
The bituminous mixture used for such patch

repairs shall be in accordance with the appropriate
Clause of these Specifications. Materials to be used
for patching shall always be of the same type and
standard of construction as, or better than, the
material being patched at the same 1evel of
construction. Materials used for patching shall never
be of lesser bearing capacity nor of a greater porosity
Page 1325 of 1427

than the adjacent previous construction. Non-
bituminous material must not be used for patching
bituminous materials. Where modified binder is to
be used, Clause 52 1 of these Specifications shall
apply.
The grading of aggregates and bitumen

content of the mix used for such patch repair shall be
in accordance with Clause 501 .
3004.2.3. Preparation of the area for pot-hole and

patch repair :
Each pot-hole and patch repair area shall be

inspected and all loose material removed. The area
shall be cut/trimmed either with jack hammers or
with hand tools suitable for the purpose, such that
the defective material responsible for the failure is
all removed and such that the excavation is of a
regular shape.
The edges of the excavation shall be cut

vertically. The area shall be thoroughly cleaned with
compressed air or any appropriate method approved
by the Engineer to remove all dust and loose
particles. Layers below the level of the bituminous
construction shall be replaced using material of the
equivalent specification to the original construction,
which shall particularly include the specified
standards of compaction. The area for bituminous
construction shall be tacked or primed with cutback
or emulsion depending upon whether the lower area
Page 1326 of 1427

is bituminous or granular in nature. The sides,
however, are to be painted with hot tack coat
material. The prime coat and tack coat shall conform
to Clauses 502 and 503 of these Specifications,
respectively.
3004.2.4. Backfilling operation : The

mixture to be used in bituminous patching shall be
either a hot mix or a cold mix in accordance with the
appropriate Clauses of these Specifications. Mixing
shall be done in a plant of suitable capacity. The
bituminous mixture shall be placed in layers of
thickness not more than 100 mm (loose) and shall be
compacted in layers with roller/plate
compactor/hand roller/rammer to the compaction
standards defined in the appropriate Clauses of these
Specifications. While placing the final layer, the mix
shall be spread slightly proud of the surface so that
after roiling, the surface shall be flush with the
adjoining surface. If the area is large, the spreading
and levelling shall be done using hand shovels and
wooden straight edges. During the process of
compaction, the surface levels shall be checked
using a 3m straight edge.
3004.2.5. Measurement fur payment:

Filling of pot-holes and patch repair shall be
measured in sq.m.

filling of pot-holes and patch repair shall be payment
in full for:
Page 1327 of 1427

(i) furnishing all materials required;
(ii) all works involved including excavation,
trimming, back filling with any non-
bituminous layers required, lacking,
priming with cutback or emulsion, and
back filling with bituminous materials;
accordance with the Specifications.
3004.3. Crack Sealing
3004.3.1. Scope: Crack sealing shall consist

of one or more of the following operations as
instructed under the Contract:
(i) Fog seal

(ii) filling cracks with a binder, or a
combination of crusher dust and a binder
(iii) by treating the crack sealing as a patch
repair.
3004.3.2. Fog seal
3004.3.2.1. Scope : Fog seal for use in

maintenance work shall conform to the requirements
of Clause 518 of these Specifications, and shall
consist of an application of emulsified bitumen,
without any aggregate cover for sealing fine hair-
cracks or for rejuvenating oxidised bituminous
surfaces. Areas having cracks with less than 3mm
Page 1328 of 1427

width shall be considered for this treatment, unless
otherwise instructed by the Engineer.
30043.2.2. Material: Bituminous emulsion

for Fog Seal shall be of a slow setting type. Where
modified binder is to be used, Clause S21 of these
Specifications shall apply.
30043.23. Application : The area to be

treated with fog seal shall be thoroughly cleaned
using compressed air, scrubbers, etc. The cracks
shall be cleaned with a compressed air jet to remove
all dirt, dust, etc. The fog seal shall be applied at the
rate of 0.5-1.0 litre/sq.m. of emulsion, or as
otherwise instructed by the Engineer, using
equipment, such as, a pressure tank, flexible hose
and spraying bar or lance. Traffic shall be allowed
on to the surface only after the seal has set to a non-
tacky and firm condition so that it is not picked up
by the traffic.
30043.2.4. Measurement for payment: The

fog seal work shall be measured in sq. metres,
calculated from the dimensions of work instructed in
the Contract or by the Engineer.

application of fog seal shall be payment in full for:
(i) supplying of fog seal material and all the

operations for applying it; and
(ii) all the labour, tools, equipment and
Page 1329 of 1427

accordance with this Specification.
3004.3.3. Crack filling
3004.33.1. Scope: Crack filling shall be

carried out using a binder of a suitable viscosity,
normally a slow-curing bitumen emulsion, as
instructed by the Engineer. For wider cracks, in
excess of an average of 3 mm in width the
application of emulsion may be preceded by an
application of crusher dust, or other fine material
acceptable to the Engineer.
3004.3.3.2. Materials: Bitumen for use in

crack sealing shall be of a slow curing type as
instructed by the Engineer. Dust for crack sealing,
when used, shall be crusher dust or some other
suitable fine material approved by die Engineer,
passing the 4.75 mm sieve but with a maximum of
10 per cent passing the 0.075 mm sieve.
3004.3.3 3. Construction: If dust is to be

used it shall be placed in the cracks before the
application of binder and the cracks filled to a level
approximately 5 mm below road surface level. The
surface of the road shall be swept clear of dust prior
to the application of binder. Binder shall be poured
into the cracks, taking care to minimise spillage. If
spillage onto the road surface does occur, dust shall
be applied to the excess bitumen until it is blotted
up.
Page 1330 of 1427

3004.3.3.4. Measurement: Crack sealing
shall be paid by the linear metre of crack as
instructed by the Engineer.
3004.3.3.5. Payment: The contract rate for

crack sealing shall be payment in full for:
(i) supplying all necessary materials and for
the work of applying them;
(ii) all labour, tools, equipment and all
incidentals necessary to complete the
work according to these Specifications.
3004.3.4. Crack prevention courses: Clause

522 spec; lies crack prevention courses. These may
be included in substantial maintenance treatments.
3004.4. Dusting
3004.4.1. Scope: Dusting shall consist of the

application of crusher dust or other fine graded
material approved by the Engineer to areas of road
where bleeding of excess bitumen is occurring.
3004.4.2. Material: Dust shall consist of

crusher dust or other graded fine material acceptable
to the Engineer, and shall generally be finer than 3.0
mm with not more than 10 per cent passing the 0.075
mm sieve.
3004.4.3. Dust shall be spread by manual

application, to the areas of road defined by the
Page 1331 of 1427

Engineer. Dust shall generally be applied during the
hottest part of the day and, when so instructed by the
Engineer, surplus dust displaced by passing traffic
shall be manually swept back onto the area where
further bleeding of excess bitumen is apparent. Dust
shall be applied at a nominal rate of 2.5 kg per
square metre.
3004.4.4. Measurement: Dusting shall be

paid for by the square metre of road surface
instructed to be dusted by the Engineer.
3004.4.5. Payment: The Contract unit rate

for dusting shall be in payment in full for:
(i) supplying all necessary materials and for
the work of applying them;
(ii) all labour, tools, equipment and all
incidentals necessary to complete the
work according to the Specifications.
3004.5. Slurry Seal
Slurry seal for use in maintenance work shall

conform to the requirements of Clause 516. Manual
methods of spreading and levelling may be used,
subject to the prior agreement of the Engineer.
3004.6. Surface Dressing for

Maintenance Work
Surface dressing for maintenance

applications shall be carried out in conformity with
Page 1332 of 1427

the requirements of Clause 510, except that the use.
of small and portable equipment shall be permitted
provided that it can be demonstrated, to the
satisfaction of the Engineer, that it can produce work
consistently in accordance with the requirements of
3004.7. Specialist Repairs
3004.7.1. Specialist repairs include repairs

of localized areas of damage to materials for which
repairs using normal hot-mix or cold-mix patching
materials are inappropriate. Such specialist repairs
will include repairs to mastic asphalt and stone
mastic asphalt.
3004.7.2. In such cases, pot-hole and patch

repairs shall be earned out in accordance with the
provisions of Clause 3004.2 above, except that the
construction to the mastic asphalt, stone mastic
asphalt or other specialist material layer shall,
subject to the instructions of the Engineer, be carried
out in accordance with the provisions of the
appropriate Clause of these Specifications.
3005. MAINTENANCE OF CEMENT

CONCRETE ROAD
3005.1. Repair of Joint Grooves with

Epoxy Mortar or Epoxy Concrete
3005.1.1 Scope : The work shall consist of
Page 1333 of 1427

repair of spalled joint grooves of contraction joints,
longitudinal joints and expansion joints in a concrete
pavement using epoxy mortar or epoxy concrete.
3005.1.2. Materials : The type/grade of

epoxy compatible with the coefficient of thermal
expansion of concrete shall be used with either
processed fine aggregate or fine stone chips to
produce a dry mix for repairing spoiled or damaged
edges.
3005.1.3. Repairing Procedure: Spoiled

or broken edges shall be shaped neatly with a
vertical cut with chisels into the shape of rectangle.
Small pneumatic chisels also may be used, provided
the cutting depth can be controlled. The depth of the
cut shall be the minimum to effect repair. After
shaping the spalled area, it shall be cleaned and
primed. The epoxy mortar/concrete is then applied
using hand tools like trowels, straight edges, brushes
etc. The repaired edge shall be in line with the joint
groove and shall be flush with the concrete slabs.
During the repair work, any damage noticed to the
joint sealant shall be made good by raking out the
affected portion and resealing.
3005.1.4. Traffic: Although the epoxy mixes

set in 2-3 hours time, it is desirable to divert the
traffic for 12 hours or as per the recommendation of
the manufacturers.
3005.1.5. Measurements for payment: Repair
Page 1334 of 1427

of joint grooves shall be measured in linear metres.
3005.1.6. Rate: The Contract unit rate for

repair of joint grooves with epoxy mortar or epoxy
concrete shall be in full compensation for:
(i) supply and application of epoxy primer,

epoxy mortar or epoxy concrete;
(ii) all tools, equipment and incidentals to
complete the work in accordance with the
above Specification.
3005.2. Repair Involving Removal of Old

Joint Sealant and Sealing - with Fresh Sealant in
Cement Concrete Pavements
3005.2.1. Scope: The repair of sealant of

contraction, longitudinal or expansion joints shall
include removal of the existing sealant and resealing
the joint with fresh sealant material.
3005.2.2. Material: Sealant material to be

replaced shall be either hot poured rubberised
bitumen or polysulphide type of sealant as per
Clause 602.2.8. As per the recommendation of the
manufacturer, appropriate type of primer also shall
be applied.
3005.2.3. Repairing procedure: The

existing sealant shall be raked out with the help of a
metal raker such that most of the sealant is removed.
Subsequently, the sealant stuck to the sides of the
Page 1335 of 1427

grooves shall be removed thoroughly either by using
saw cutting machine so that grooves may be widened
by one mm or by sand blasting. In no case the old
sealant shall be present during reseating operation. If
joint grooves are found inadequate in depth, they
shall be deepened as directed by the Engineer.
Before commencing the sealing operation,

compressed air shall be used to clean the joint
grooves to clean the joint groove. A heat resistant,
paper backed compressible debonding strip or tape
should be inserted in accordance with the
requirement of Clause 602.11.2. Sealant may be
poured either using hand held poorer or using
mechanised sealing machines. Sealants should not be
heated directly but in double jacketed machine. All
precautions and arrangements shall be taken not to
spill the sealant on the concrete pavement The
sealant may be poured to a depth of 5 ± 2 mm from
.the pavement surface.
3005.2.4. Measurements for payment:

Repair of joint sealant shall be measured in linear
metres.
3005.2.5. Rate: Contract unit rate for repair,

of joint sealant shall be in full compensation for
(i) removal of old sealant, regrooving or

sand blasting the sealing groove and
placing of debonding strip or tape.
(ii) all tools, equipments and incidentals to
Page 1336 of 1427

complete the work in accordance with
the above Specification.
Page 1337 of 1427

Reinforced Earth
3100
Reinforced Earth
Page 1338 of 1427

3101. SCOPE
The work covers the construction of

reinforced earth structures, together with the
construction of earthwork in layers, assembly and
erection of reinforcing elements and placement of
facing panels and all associated components.
3102. REINFORCING ELEMENT
3102.1. The reinforcing element shall be of

Geotextile, aluminium alloy strip, copper strip,
carbon steel strip, mats of metal or synthetic grids, or
any other proprietary material which may be
approved by the Engineer and indicated on the
drawings.
3102.2. Geotextile
The material shall conform to Clause
701.2.6.
3102.3. Aluminium alloy strip shall comply

with BS:1470 quality 5454 in the H 24 condition.
3102.4. Copper strip shall comply with

BS:2870 quality C 101 or C 102 in the 1/2 H
condition and shall have 0.2 per cent proof stress of
not less than 180 N/mm2.
3102.5. Carbon steel strip which shall be

galvanized shall comply with BS:1449 (Part 1),
Page 1339 of 1427

either quality KHR 34/20 P or quality 50/35 P, each
having a silicon content of not less than 0.25 per cent
and not more than 0.40 per cent. The fabricated
element shall be galvanized in accordance with
BS:729, and the average zinc coating weight for any
individual test area shall not be less than 1000
gm/sq.m.
3102.6. Stainless steel strip shall comply with

BS: 1449 (Part 2) quality 316 S 31 or 3/6 S 33
except that the material shall be cold rolled to
provide a 0.2 per cent proof stress of not less than
400 N/sq. mm and the tensile strength shall not be
less than 540 N/sq. m.
3102.7. All metallic components buried in

soil shall be of electrolytically compatible materials.
3102.8. Geogrids
The supply of geogrids shall carry a

certification of BIS or ISO 9002 for all works. While
the reinforcing element for wall or slope portion
shall be with mono oriented Geogrid, the
reinforcement for the foundation of a reinforced
earth wall or slope shall be with bi-directionally
oriented Geogrid. For mono oriented Geogrid, the
characteristic design tensile strength at a strain not
exceeding 10 per cent in 100 years shall be at least
40 kN/m when measured as per GR1:GG3. The
strength for bi-directionally oriented Geogrid in the
longitudinal direction shall be at least 40 kN/m at a
Page 1340 of 1427

maximum elongation of 15 per cent. The Geogrid
shall be inert to all naturally occurring chemicals,
minerals and salts found in soil.
3103. EARTH FILL
The fill material for reinforced earth

structures shall have an angle of interface friction
between the compacted fill and the reinforcing
element of not less than 25°C, measured in
accordance with IS : 13326 (Part 1). The soil should
be predominantly coarse grained; not more than 10
per cent of the particles shall pass 75 micron sieve.
The soil should have properties such that die salts in
the soil should not react chemically or electrically
with die reinforcing elements in an adverse manner.
3104. FACIA MATERIAL
3104.1. The facing shall comprise of one of

following :
(i) Reinforced concrete (Cast m

situ or precast) slabs
(ii) Plain cement concrete form
fill hollow block (Precast)
(iii) Masonry construction, Rubble
facia
(iv) Other proprietary and patented
proven system
The facing shall be sufficiently flexible to
Page 1341 of 1427

withstand any deformation of the fill.
3104.2. Facia unit joint filler should be

durable resistant to the effect of air pollution and
water/saline water.
3104.3. Bedding material shall consist of

either cement mortar or a durable gasket seating such
as resin bonded cork strip.
3104.4. Connection between the facia and the

reinforcing element 1 be by using polyethylene
strips/rods, fibre glass dowels or any other material
shown in the drawing. Any other material used shall
be tested to provide 100 per cent joint strength as of
parent element in continuity.
Overlapping in principal reinforcement or in

the joint shall ensure load transfer through joints,
perpendicular to the direction of laying.
3105. CONSTRUCTION DETAILS
3105.1. The plan area of the reinforced earth

structure shall be, excavated to provide a nominally
level base which may be stepped at the back as
required to receive the horizontal reinforcing
element grid.
The depth of the foundation below the

finished ground level at the foot of the slope or wall
shall not be less than 1000 mm.
Page 1342 of 1427

Additional strip footing, trough guide made
of concrete or anchor key pad shall be provided at
founding level to receive the facia or the bottom
most reinforcement connection. This shall have
adequate soil cover against erosion and scour in
particular cases.
3105.2. Orientation
The reinforcing elements shall be placed at

right angles to the face of the wall, with greater
cross-sectional dimension in die horizontal plane.
The placement of the elements including their
vertical/horizontal spacing and length shall be as in
the drawing.
31053. Facing Batter
It may be necessary to set facing unit at an

additional batter than as provided in the drawing as
there is a tendency for initially positioned units of
facia to lean outward as the fill material is placed
and compacted. Care and caution shall be taken to
rectify this phenomenon.
3105.4. Drainage
Drainage shall be provided as per drawing

given in detail. The retained fill shall have a suitably
designed drainage bay to allow free draining of the
reinforced fill.
Page 1343 of 1427

3105.5. Laying and Compacting
The reinforcing elements shall be laid free

from all kinks, damage and displacement during
deposition, spreading, levelling and compaction of
the fill. The programme of filling shall be such that
no construction plant runs directly on the
reinforcement.
All construction plant having a mass

exceeding 1000 kg shall be kept at least 1.5 m away
from the fact of slope or wall. In this area (upto 1.5m
from the face of slope or wall), following
compaction plant shall be used :
(i) Vibratory roller having a weight per

metre width of roll not exceeding 1300
kg with total weight not exceeding
10,000 kg.
(ii) Vibratory plate compactor of maximum
weight 1000kg.
(iii)Vibro tamper having a weight not
exceeding 75 kg.
Compaction by any other method like using

dozer or back blade compaction by dozer or
excavator bucket shall be permitted with due
approval from the Engineer after ascertaining the
level of compaction so achieved.
During construction of reinforced fill, the
Page 1344 of 1427

retained material beyond the reinforcement at the
rear or the structure shall be maintained at the same
level as reinforced fill.
The compacted layer shall not be more than

200 mm, to achieve compaction of 95 per cent of
maximum laboratory density where measured per IS
: 2720 (Part 8). Temporary formwork shall be used
to support the construction as per specified details
given in the drawing. The forms, scaffolding and
props shall be sufficient in numbers to allow taking
up of sectoral construction schedule specified in the
design.
Measurement for reinforcing elements shall

be in linear metre for anchor strips or in sq.m. for
geogrid / geotextile etc.
The measurement for facia shall be in sq.

metres. The measurement far foundation for facia
and capping beam shall be in linear metres.
Measurement for compacted earthfill shall be in
cubic metres for compacted soil.
3107. RATES
Rate shall include cost of labour, plant hire,

material storage and handling expenses, for
completing the works.
Page 1345 of 1427

Rate for providing reinforcing elements shall
include material cost, all transportation costs and
storage of the same as per special provisions. The
rate shall also include cost of laying of the
reinforcing elements including all overlaps, jointing
or stitching, heat bonding or extension.
Rate for facia fixing shall include cost of

joints, all necessary temporary formwork,
scaffolding and all lifts and leads, if any, as shown n
the drawing, unless otherwise specified to the treated
separately along with foundation or slope/wall kerb
at the top of slope or wall. Rate for bed block and
capping beam shall include all items of excavation,
concrete, reinforcing steel, formwork, labour and
equipment.
Rate for soil fill shall include compaction as

desired in requisite layers through mechanical
means, cost of hire or labour for plant operations,
dressing and levelling slopes, including special
measures for edge reinforcements as shown in the
drawing.
Page 1346 of 1427

Appendices
Appendices
Page 1347 of 1427

Appendix-1
LIST OF IRC PUBLICATIONS REFERRED TO

IN THE SPECIFICATIONS
Number Title
Designation
IRC : 2-1968 Route Marker Signs for National
Highways (First Revision)
IRC : 5-1998
Standard Specifications & Code of
Practice for Road Bridges.
IRC : 6-2000 Section I - General Features of
Design (Seventh Revision)
IRC : 8-1980 Standard Specifications & Code of

Practice for Road Bridges, Section
IRC : 10-1961 II - Loads and Stresses (Fourth
Revision)
IRC : 14-1977 Type Designs for Highway

Kilometre Stones (Second
Revision)
IRC: 16-1989
Recommended Practice for
Borrowpits for Road Embankments
IRC : 17-1965 Constructed by Manual Operation
Recommended Practice for 2 cm

IRC: 18-2000 Thick Bitumen and Tar Carpets
(Second Revision)
Page 1348 of 1427

IRC : 19-1977 Specification for Priming of Base
Course with Bituminous Primers
(First Revision)
IRC : 20-1966
Tentative Specification for Single
Coat Bituminous Surface Dressing
IRC : 21 -2000
Design Criteria for Prestressed
Concrete Road Bridges (Post-
Tensioned Concrete) (Third
IRC : 22-1986 Revision)
Standard Specification and Code of

Practice for Water Bound
IRC : 23-1966 Macadam (Second Revision)
Recommended Practice for

IRC : 24-2001 Bituminous Penetration Macadam
(Full Grout)
IRC : 25-1967 Standard Specifications and Code

of Practice for Road Bridges,
IRC : 26-1967 Section III - Cement Concrete
(Plain and Reinforced) (Third
Standard Specifications and Code

IRC : 29-1988 of Practice for Road Bridges,
Section VI - Composite
Construction for Road Bridges
IRC : 30-1968 (First Revision)
Page 1349 of 1427

Tentative Specification for Two
IRC : 35-1997 Coat Bituminous Surface Dressing

IRC : 36-1970 of Practice for Road Bridges.
Section V - Steel Road Bridges
(Second Revision)
IRC : 37-2001
Type Designs for Boundary Stones
IRC : 40-1970 Type Designs for 200-Metre

Stones
IRC : 45-1972 Tentative Specifications for

Bituminous Macadam (Base &
Binder
Course)
IRC : 47-1972
Specification for Bituminous
IRC : 48-1972 Concrete (Asphaltic Concrete) for
Road Pavement (First Revision)
IRC : 49-1973 Standard Letters and Numerals of

Different Heights for Use on
Highway Signs
IRC : 50-1973
Code of Practice for Road
Markings (with Paints) (First
IRC : 56-1974 Recommended Practice for the
Page 1350 of 1427

Construction of Earth
IRC . 63-1976 Embankments for Road Works
Guidelines for the Design of

IRC : 67-2001 Flexible Pavements (Second
Revision)
IRC : 72-1978
IRC : 75-1979 Section IV - (Brick, Stone and
Block Masonry) (First Revision)
IRC : 78-2000
Recommendations for Estimating
the Resistance of Soil below the
IRC : 79-1981 Maximum Scour Level in the
Design of Well Foundations of
IRC : 82-1982 Bridges
Tentative Specification for Built-

IRC : 83-1999 up Spray Grout
Tentative Specification for

Bituminous Surface Dressing
IRC : S3-1987
Using
Precoated Aggregates
IRC : 87-1984 Recommended Practice for the

Pulverization of Black Cotton Soils
for Lime Stabilisation
IRC : 89-1997
Recommended Design Criteria for
the Use of Cement Modified
Page 1351 of 1427

IRC : 90-1985 Soil in Road Construction
Guidelines for the Use of Soil

IRC : 93-1985 Lime Mixes in Road Construction
(First Revision)
IRC : 94-1986 Recommended Practice for

Treatment of Embankment Slopes
for
IRC: SP:11- Erosion Control
1988 Tentative Guidelines for the Use of
Low Grade Aggregates and
IRC:SP:31- Soil Aggregate Mixtures in Road
1992 Pavement Construction
IRC : HRB : Code of Practice for Road Signs

Special Report (First Revision)
11, 1992
Recommended Practice for Use
and Upkeep of Equipment, Tools
and Appliances for Bituminous
Pavement Construction
Guidelines for the Design of High

Embankments

Section VII - Foundation &
Substructure (Second Revision)
Recommended Practice for Road
Page 1352 of 1427

Delineators
Code of Practice for Maintenance

of Bituminous Surface of
Highways

Section IX - Bearings, Part I:
Metallic Bearings (First Revision)

(Part-ll) Section IX - Bearings, Part
II: Elastomeric Bearings
Guidelines for the Design &

Erection of False Work for Road\
Bridges
Guidelines for Design &

Construction of River Training and
Control Works for Road Bridges
(First Revision)
Guidelines of Selection, Operation

and Maintenance of Bituminous
Hot Mix Plant
Guidelines on Design and

Installation of Road Traffic Signals
Page 1353 of 1427

Specifications for Dense
Bituminous Macadam
Handbook of Quality Control for

Construction of Roads and
Runways (Second Revision)
New Traffic Signs
Ministry of Shipping & Transport

(Roads Wing) Handbook on
Road Construction Machinery
(1985)
IRC Highway Research Board,

State of Art: Granular and Bound
Bases and Sub-Bases
Page 1354 of 1427

Appendix-2
LIST OF INDIAN AND FOREIGN

STANDARDS REFERRED TO IN THE
SPECIFICATIONS
Number Title
Designation
(A) INDIAN STANDARDS
IS:5-1994 Colour for ready mixed paints and enamels (fourth
IS:73-1992 Paving Bitumen-Specification (second revision)
IS: 164-1981 Ready mixed paints, brushing, for road markin

Colour No. 356 Golden yellow, white and black
IS:210-1993 Grey iron castings (fourth revision)
IS:215-1995 Road tar specification (third revision)
IS:217-1988 Cutback Bitumen-Specification (second revision)
IS:269-1989 33 grade ordinary portland cement (fourth revisio
IS:278-1978 Galvanized steel barbed wire for fencing (third re
IS:280-1978 Mild steel wire for general engineering purposes (
IS:334-l982 Glossary of terms relating to bitumen und tar (sec
IS:383-1970 Coarse and fine aggregates from natural sources

revision)
Page 1355 of 1427

IS:432-1982 Mild steel and medium tensile steel bars and har
concrete reinforcement
(Part I) Mild steel and medium tensile steel bars (third rev
(Part II) Hard-drawn steel wire (third revision)
IS:443-1975 Methods of sampling and test for rubber hoses (se
IS:454-1994 Cutback Bitumen from Waxy Crude-Specification
IS:455-1989 Portland stag cement (fourth revision)
IS:456-2000 Code of practice for plain and reinforced concrete
IS:458-1988 Precast Concrete pipes (with and without

revision)
IS:460-1985 Test sieves
IS:508-1987 Specification grease graphited (fourth revision)
IS.516-1959 Methods of test for strength of concrete
IS:702-1988 Industrial bitumen (second revision)
IS:736-1986 Wrought aluminium and aluminium alloys,

engineering purposes (third revision)
IS:814-1991 Covered electrodes for manual metal arc welding
manganese steel (fifth revision)
IS:1030-1998 Carbon steel castings for general engineering purp
IS: 1077-1 992 Common burnt clay building bricks (fifth revision
Page 1356 of 1427

IS:1124-1974 Method of test for water absorption apparent
porosity or natural building stones (first revision)
IS:1129-1972 Dressing of natural building stones (first revision)
IS:1148-1982 Hot rolled rivet bars (upto 40 mm dia) for stru

revision)
IS:1149-1982 High tensile rivet bars for structural purposes (thir
IS:1195-1978 Bitumen mastic for flowing (second revision)
IS:1199-1959 Method of sampling and analysis of concrete
IS:1201 to Indian standard methods for testing tar and bitumi

1220-1978
IS:1203-1978 Determination of penetration (first revision)
IS:1205-1978 Determination of softening point (first revision)
IS:1206-1978 Determination of viscosity (first revision)

(Part 1 to 3)
IS:1208-1978 Determination of ductility (first revision)
IS:1209-1978 Determination of flash point and fire point (first re
IS:1212-1978 Determination of loss of heating (first revision)
IS:1216-1978 Determination of solubility in carbon disulphidc

or trichorocthylene (first revision)
Page 1357 of 1427

IS:1217-1978 Determination of mineral matter (ash) (first revisi
IS: 1239-1990 Mild steel tubes (fifth revision)

(Part 1)
IS:1239-1992 Mild steel tubular and other wrought steel pipe fit
(Part 2)
IS:1364-1992 Hexagon head bolts, screws and nuts of product g

(Part I to V) : Hexagon head bolts (size range Ml.6 to M64) (th
IS:367-1997 Technical supply conditions for threaded steel fas

(Part I to XX)
IS:1387-1993 General requirements for the supply of metallurg

revision)
IS:1398-1982 Packing paper, waterproof, bitumen-laminated (se
IS:1448 Method of tests for petroleum and its products
IS:1477 Code of practice for painting of ferrous metals in
(Part 1)-1971 Pretreatment (first revision)
(Part 2)-1971 Painting (first revision)
IS:1489-1991 Portland-pozzolana cement
(Part 1) Flyash based (third revision)
Page 1358 of 1427

(Part 2) Calcined clay based (third revision
IS. 1498-1970 Classification and identification of soils for
purposes (first revision)
IS: 1514-1990 Methods of sampling and test for quick lime an
revision)
IS 1732-1989 Dimensions for round and square steel bars for
engineering purposes (second revision)
IS: 1785 Plain hard-drawn steel wire for prestressed concre
(Part 1)-1983 Cold-draws stress relieved wire (second revision)
IS:1786-1985 High strength deformed steel bars and

reinforcement (third revision)
IS: 1838 Preformed filler for expansion joint in con
structures (non extruding and resilient type)
(Part 1)-1983 Bitumen impregnated fibre (first revision)
IS:1888-1982 Method of load tests on soils (second revision)
IS:2004-1991 Carbon steel forging for general engineering purp
IS:2062-1999 Steel to general structural purpose (fifth revision)
IS:2116-1980 Sand for masonry mortals (first revision)
IS:2131-1981 Methods for standard penetration test for soils (fir
IS:2250-1981 Code of practice for preparation and use of m

revision)
Page 1359 of 1427

IS:2386-1963 Methods of test for aggregates for concrete
(Part 1) Particle size and shape
(Part 2) Estimation of deleterious materials and organic im
(Part 3) Specific gravity, density, voids, absorption and bu
(Part 4) Mechanical properties
(Part 5) Soundness
(Part 6) Measuring mortar making properties of fine aggre
(Part 7) Alkali - Aggregate reactivity
(Part 8) Petrographic examination

IS-2720 Methods of test for soils
(Part 2)-1973 Determination of water content (second revision)
(Part 3)-1980 Determination of specific gravity (first revision)
Section 1 Fine grained soils
Section II Medium and coarse grained soils
(Part 4)-1985 Grain size analysis (second revision)
(Part 5)-1985 Determination of liquid and plastic limits (second
(Part 7)-1980 Determination of moisture content/dry density

compaction (second revision)
(Part 8)-1983 Determination of water content-dry density relatio
Page 1360 of 1427

compaction (second revision)
(Part 10)-1991 Determination of unconfined compressive strengt
(Part 13)-1986 Direct shear test (second revision)
(Part 14)-1983 Determination of density index (relative density)

(first revision)
(Part 16)-1987 Laboratory determination of CBR (second revisio
(Part 27)-1977 Determination of total soluble sulphates (first revi
(Part 28)-1974 Determination of dry density of soils in-place by

method (first revision)
(Part 29)-1975 Determination of dry density of soils in-place b

(first revision)
(Part 37)-1976 Determination of sand equivalent values of soils a
(Part 40)-1977 Determination of free swell index of soils
IS:3117-1965 Specification for bitumen emulsion for roads (anio
IS:3466-1988 Masonry cement (second revision)
IS:3764-1992 Code of safety for excavation work (first revision
IS:4138-1977 Safety code for working in compressed air (first re
1S:4332 Method of test for stabilized soils
Page 1361 of 1427

(Part 1)-1967 Method of sampling and preparation of stabilized
(Part 3)-l967 Test for determination of moisture content-dry de

stabilized soil mixtures
(Part 4)-l968 Wetting and drying and, freezing and thawing test
soil-cement mixtures
(Part 5)-l970 Determination of unconfined compressive strengt
(Part 7)-l973 Determination of cement content of cement stabil
(Part 8)-1969 Determination of lime content of lime stabilized s
IS:4434-1978 Code of practice for in-situ vane shear test for soil
IS:1826-1979 Hot dipped galvanised coating on round steel wire
IS:5317-1987 Specification for bitumen mastic for bridge deckin

revision)
IS:5435-1987 General requirements for cold asphalt macadam m

revision)
IS:5640-1970 Method for determining the aggregate impact valu

aggregate
IS:6006-1983 Uncoated stress relieved strands for prestressed c

revision)
IS:6241-1971 Methods of test for determination of stripping val
Page 1362 of 1427

IS:6909-1990 Supersulphated cement
IS:6925-1973 Methods of test for determination of water solubl

admixtures
IS:7537-1974 Road traffic signals
IS:7623:1993 Specification for lithium base grease for indust

revision)
IS:8041-1990 Rapid hardening portland cement (second revision
IS:8112-1989 43 grade ordinary portland cement (first revision)
IS:8500-1991 Structural steel - microalloyed (medium and hi

(first revision)
IS:8887-1995 Bitumen emulsion for roads (cationic type)-specif
IS:9103-1999 Admixtures for concrete (first revision)
IS:9381-1979 Methods of testing tar and bituminous materi

fraass breaking point of bitumen
IS:9382-1979 Methods of testing tar and bituminous materials: d

of heat and air by thin film oven tests
IS:10262-1982 Guidelines for concrete mix design
IS:12269-1987 Specification for 53 grade ordinary portland ceme
Page 1363 of 1427

IS:12330-1988 Specification for sulphate resisting portland ceme
IS:13321 Glossary of terms for geosynthctics, part 1: terms

(Part 1)-1992 properties
IS:13325-1992 Determination of tensile properties of extruded p

the wide strip-test method
IS:13326 Evaluation of interface friction between geosynth

(Part I)-1992 of test, part 1 : modified direct shear technique
IS:SP 23-1982 Handbook on concrete mixes (based on Indian sta
(B) FOREIGN STANDARDS
ASTM : D-36 Thermoplastic material
ASTM : D-395 Compression test of vulcanized rubber
ASTM : D-412 Tension testing of vulcanized rubber
ASTM : D-429 Adhesion of vulcanized rubber to metal
ASTM : D-573 Accelerated aging of vulcanized rubber by th
ASTM : D-624 Tear resistance of vulcanized rubber
ASTM : D-664 Test method for neutralisation number for po
ASTM : D-797 Young’s modulus in flexure of elastomer at n

temperature
Page 1364 of 1427

ASTM : D977-91 Standard specification for emulsified asphalt
ASTM : D979-89 Standard practice for sampling bituminous pa
ASTM : D-1075 Effect of water on cohesion of compacted bit
ASTM : D-l 149 Accelerated ozone cracking of vulcanized rub
ASTM : D-l559 Test for resistance to plastic flow of bitum

Marshall apparatus
ASTM : D2026-72 Standard specification for cutback asphalt (sl

(Reapproved 1993)
ASTM : D2027-76 Standard specification for cutback asphalt (m

(Reapproved 1992)
ASTM : D2041-95 Standard test method for theoretical maximu

density of bituminous paving mixtures
ASTM : D2172-95 Standard test methods for quantitative extra

bituminous paving mixtures
ASTM : D-2240 Indentation hardness of rubber and plas

Durometer
ASTM : D2397-94 Standard specification of canonic emulsified
ASTM : D3203-94 Standard test method for per cent air voids in
open bituminous paving mixtures
ASTM : D-3625
Page 1365 of 1427

Test method for effect of water on bitumen c
boiling water
ASTM : D3910-90
(Reapproved 1995) Standard practice for design, testing and cons
ASTM : D-4533
Test method for trapezoid tearing strength of
ASTM : D5976-96
Standard specification for type I polymer mo
for use in pavement construction
ASTM : E-11
Specification for wire cloth sieves for testing
ASTM : E-810
Test method for coefficient of retro-reflect
sheeting
AASHTO:DM 283
Coarse aggregate for highway and airport con
AASHTO:DM 294-70
Fine aggregate for bituminous paving mixtur
AASHTO:DM 288-82
Geotextiles used for subsurface drainage purp
AASHTO:DM 17-77
Mineral filler for bituminous paving mixtures
AASHTO:DR 5-80
Selection and use of emulsified asphalts
AASHTO:DM 81-75
Cut-back asphalt (rapid-curing type)
AASHTO:DM 82-75
Cut-back asphalt (medium-curing type)
AASHTO:DM 140-80 Emulsified asphalt
AASHTC:DM 57-80 Materials for embankments and sub grades
Page 1366 of 1427

AASHTO:DM 147-65 Materials for aggregate and soil-aggregate
(1980) surface courses
AASHTO:DM 216-68 Lime for stabilization
AASHTO:DM 249-79 White and yellow reflective thermoplasti

(solid form)
AASHTO:DM 268-77 Weatherometer
AASHTO:DM 282-80 Joint sealants, hot poured, elastomeric type,

for Portland cement concrete pavements
AASHTO: M82 Equivalent to ASTM:D2027-76 or ASTM:D2
AASHTO: MI40 Equivalent to ASTM:D977-91
AASHTO: M208 Equivalent to ASTM:D2397-94
AASHTO: T182-84 Coaling and stripping of bitumen aggregate m
AASHTO: T283-89 Resistance of compacted bituminous mixtur

damage
BS:410-1969 Test sieves
BS:434 Bitumen road emulsions (anionic and cationi
- Part 2:1984 Specification for bitumen road emulsion
Page 1367 of 1427

-Part 2:1984 Code of practice for use of bitumen road emu
BS : 598 Sampling and examination of bituminous m

other paved areas
- Part 104:1987 Methods of test for the determination

compaction
- Part 107:1990 Method of test for the determination of the

wearing course rolled asphalt
BS : 729-1971 Hot dip galvanized coating on iron and steel
BS : 812-1975 Testing aggregates
- Part 2 Methods for determination of physical proper
- Part 3 Methods for determination of mechanical pro
- Part 111 Method for determination of ten per cent fine
- Part 114-1989 Method for determination of the polished-sto
BS : 1047-1952 Air-cooled blast furnace slag coarse aggregat
BS : 1154-1970 Vulcanized natural rubber compounds
BS : 1377-1975 Methods of test for soils for civil engineering
BS : 1447-1973 Mastic asphalt (limestone fine aggregates) fo
BS : 1449-1956 Steel plate, sheet and strip
Page 1368 of 1427

- Part 1-1972 Carbon steel plate, sheet and strip
- Part 2-1967 Stainless and heat resisting plate, sheet and st
BS : 1470-1972 Wrought aluminium and aluminium alloys fo

purposes - plate, sheet and strip
HS : 2000 Methods of test for petroleum and its product
- Part 397:1995 Recovery of bitumen binders-dichlorometh

film evaporator method
BS : 2630 Preformed joint Tiller
BS : 2870 Rolled copper and copper alloys : sheet, strip
BS : 3262 Hot-applied thermoplastic road marking mate
Part-1 Specification for constituent materials and m
Part-2 Specification for road performance
Part-3 Specification for application of material to ro
BS : 5212 Part 2 1975 Cold poured joint sealants for concrete pavem
BS : 6044 Specification for pavement marking paints
BS : 6088 Specification for solid glass beads for use w

compounds and for other industrial uses
Page 1369 of 1427

BS : 6906 Methods of test for geotextiles
Part 1 Determination of the tensile properties using
Part 2 Determination of the apparent pore size distri
Part 3 Determination of water flow normal to the pl

under a constant head
Part 4 Determination of the puncture resistance (CB
Part 7 Determination of in-plane water flow
BS : 7542 Method of test curing compound for concrete
CRRi & IOC. Bituminous road construction hand book

New Delhi
BS : DD232-1996 Method for determination of the maximum

bituminous mixtures without excessive binde
Asphalt Institute The asphalt handbook, manual series No.4 (M

Manual series No.2 (MS-2) - mix design
concrete and other hot-mix types
Manual series No.14 (MS-14)- asphalt cold m
GRI-GG1 Geogrid rib tensile strength
GRI-GG2 Geogrid junction strength
GRI-GG3 Tensile creep testing of georgids
Page 1370 of 1427

(GRI denotes standards for test prepared by Geosynthetic
Drexel University. Philadelphia. USA)
Page 1371 of 1427

Appendix-3
(Clause 402.3.2 and 403 3.2)
METHOD OF SIEVING FOR WET SOILS TO

DETERMINE THE DEGREE OF
PULVERISATION
1. A sample of pulverised soil approximately 1

kg in weight should be taken and weighed
(W1).
2. It should be spread on the sieve and shaken
gently, care being taken to break the lumps of
soils as little as possible. Weight of soil
retained on the sieve should be recorded
(W2). Lumps of finer soils in the retained
material should be broken until all the
individual particulars finer than the aperture
size of the sieve are separated.
3. The soil should again be placed on the sieve
and shaken until sieving is complete. The
retained material should be weighed (W3).
4. Weight of soil by per cent passing the sieve
can than be calculated from the expression:
(W1 - W2 ) x 100
(W1 - W3 )
Page 1372 of 1427

Appendix-4
GUIDELINES ON SELECTION OF THE

GRADE OF BITUMEN
(Source : Bituminous Road Construction

Handbook, Indian Oil Corporation
and Central Road Research
Institute)
A) For bituminous premix carpel, choice is

governed by climatic conditions and
intensity of traffic.
i) Grade 30/40 for areas where

difference between maximum and
minimum atmospheric
temperatures is less than 25* C and
traffic intensity is greater than
1500 commercial vehicles per day.
For traffic intensity less than 1500
commercial vehicles per day.
Grade SO/60 is preferred.
ii) Where the difference between
maximum and minimum
atmospheric temperature is more
than 25o C and traffic intensity is
greater than 1500 commercial
vehicles per day. Grade 50/60 may
be used. For traffic intensity of less
than 1500 commercial vehicles per
day, Grade 80/100 may be used.
Page 1373 of 1427

For roads with very heavy traffic
greater than 4500 commercial
vehicles per day, such as
metropolitan city roads. Grade
30/40 is preferred.
iii) Grade 80/100 may be used in high
altitude and snow-bound regions,
irrespective of traffic intensity
consideration.
B) For bituminous macadam and

penetration macadam as also built-up
spray grout. Grade 30/40 (for hot
climates) and 60/70 or 30/100 for ether
climates are suggested.
C) For a dense-graded bituminous

concrete, a more viscous grade like
60/70 can withstand stresses of heavier
wheel loads better than a less viscous
grade at 80/100. Similarly paving
bitumen grade 60/70 is more
advantageous for roads with large
number of repetitious of wheel loads
like expressways, urban roads, factory
toads etc High stability requirement
cannot be met effectively by less
viscous bitumen.
D) A more viscous grade of bitumen is

advantageous in reducing stripping of
bitumen film from aggregates in the
Page 1374 of 1427

presence of water.
E) With rounded river shingles, a more

viscous grade of bitumen compensates
lo some extern for poor mechanical
interlock. A comparison of penetration
grades and viscosity grades (AC-2.5 to
AC-40) of asphalt cement and AR
grades (based on Rolling Thin Film
Oven Test residue) is shown below.
Page 1375 of 1427

Page 1376 of 1427
Page 1377 of 1427
Page 1378 of 1427
Appendix-5
ANTI-STRIPPING AGENTS USED FOR

BITUMINOUS MATERIALS AND MIXES
1. Scope
1.1. Anti-stripping agents are used for

bituminous materials and mixes to ensure adhesion
between aggregates (hydrophilic in nature) and
bitumen, even under submergence in water. Prior
approval of the Engineer shall be taken in respect of
both qualitative arid quantitative use of a particular
product.
2. Materials
2.1. The anti-stripping agents shall be fatly

acid amines having a long hydrocarbon chain.
2.2. Physical and Chemical Requirements :

The anti-stripping agents shall conform to the
physical and chemical requirements as detailed in
Table A5-1.
2.3. Storage and Handling : Anti-stripping

agents shall be properly stored in closed containers
made of steel or aluminium. Containers made of
zinc, copper, polythene PVC and most types of
rubber are not suitable for use. As most of the anti-
stripping agents cause irritation when in contact
with human skin and are also irritating to the eyes,
Page 1379 of 1427

protective gloves for hands and goggles for the eyes
shall be used while handling them, specially in case
of liquid anti-stripping agents.
3. Use in Sprayed Work
3.1. Additive Dosage: The dosage shall

be determined depending on the nature (stripping
value) of the aggregate and the size of aggregate.
While the recommended minimum do:; of anti-
stripping agent for sprayed work is given in Table
A5-2, the actual dosage shall be determined in the
laboratory as directed by the Engineer.
3.2. Mixing Procedure During

Construction: The anti-stripping agent supplied in
liquid, solid or concentrate form shall be thoroughly
mixed with liquid bituminous material or with
straight run bitumen. When used with straight run
bitumen, the correct dose of anti stripping agent shall
be mixed in a hot bitumen tank boiler.
The two constituents shall be agitated till the

anti-stripping agent is thoroughly mixed. The dose of
anti-stripping agent shall suitably be increased if the
binder is to remain in bitumen boiler for a longer
period.
4. Use in Premix Work
4.1. Additive Dosage: The dosage shall be

determined depending on the nature (stripping value)
Page 1380 of 1427

of the aggregate and the per cent voids in the mix.
While the recommended minimum doses for
different types of bituminous premix materials in
terms of voids content arc given in Table AS-3, the
actual dosage shall be determined in the laboratory
TABLE A5-1. SPECIFICATION FOR
ANTISTRIPPING COMPOUND
S.NO. Test Method
1. Appearance Visual
2. Odour Smelling
3. Specific gravity 27oC IS : 1202-1978
4. Pour point C Maximum IS : 1448
5. Flash point (COC) IS : 1448
Minimum
6. Water Content per cent IS : 1448
Vol. Maximum
7. Solubility in diesel oil As given at the end of
(HDO or LDO) in the ratio Appendix
of 2:98 at 50oC
8. Total base value mg KOH/g ASTMD664
minimum
9. Nitrogen content per cent Elemental Analyser
Wt. minimum
10. Stripping value with IS :6241 As given at
bitumen containing 1 per the end of Appendix
cent Wt anti stripping
compound at 400 C 24
hours
Page 1381 of 1427

11. Under water coating test -do-
12. Thermal stability at 1630C -do-

5hours
13. Boiling water test per cent ASTM D 3625
minimum coating
14. Retained Marshall Stability As given at the. end of
per cent minimum appendix
TABLE A5-2. TENTATIVE RECOMMENDED

MINIMUM DOSE OF ANTISTRIPPING
AGENT FOR SPRAYED WORK
Aggregate Dose of anti stripping agent in percent by w

stripping
value
Surface Penetration Surface
dressing with Macadam/ Dressing w
precoated Built up spray uncoated
aggregate grout aggregate
0-25 0.5 0.6 0.7
25-50 0.6 0.7 0.8
50-100 0.75 1.0 1.0
4.2. Mixing Procedure During

Construction : The required dose of the anti-
stripping agent shall be poured into the hot bitumen
tank and allowed 15 to 30 minutes of circulation or
stirred to ensure a homogeneous mix. It is necessary
to use a stable anti stripping agent or increase the
Page 1382 of 1427

dose according to expected degradation.
Alternatively, the correct dose shall be injected into
the bitumen line by means of a pump. The agent is
fed into the bitumen first before it is sprayed on the
aggregate in the mix; thus, no separate mixing time
for mixing die agent with bitumen is required. In
rolled asphalt and bitumen mastic surfacing works,
precoated chippings are pressed into the hard surface
while the mix is still tot to make the newly hid
surface skid resistant. These chippings shall be
precoated with bitumen treated with anti striping
compound.
TABLE A5-3. TENTATIVE RECOMMENDED

MINIMUM DOSE OF ANTISTRIPPING
COMPOUND IN BITUMEN PREMIX WORKS
Stripping Dose of anti stripping agent in per cent by weight

value of
aggregate
Voids content 3-5 Voids content 5- 10 V
per cent per cent p
0-25 0.3 0.4
25-50 0.4 0.5
50-100 0.6 0.8
TESTING PROCEDURE FOR SOLUBILITY

OF ANTISTRIPPING AGENT IN DIESEL OIL
Procedure: 98ml of diesel oil (HDO or
Page 1383 of 1427

LDO) and 2 ml of antistripping agent shall be taken
in a measuring cylinder with stopper. The cylinder
along with its contents shall be kept in water bath,
maintained at 500 + 10C for half an hour. It shall then
be taken out from water bath and shaken vigorously
for 10 minutes. The stopper shall be removed and the
cylinder kept in water bath for half an hour and
examined for separation or settlement.
Reporting of results: An antistripping agent

is reported to be completely soluble in diesel oil if no
separation or settlement is observed for half an hour.
TESTING STRIPPING VALUE OF

AGGREGATES USING BITUMEN WITH
VARYING PERCENTAGES OF
ANTISTRIPPING AGENT.
Procedure: Coarse aggregate passing 19 mm

sieve and retained on 13.2 mm sieve shall be washed
and dried in an oven for 24 hours at 1100C. Such
dried 200 gms of coarse aggregates shall be heated at
149° C and then mixed with 80/100 penetration
grade bitumen 5 per cent by weight of coarse
aggregate heated upto 163° C. The mixture shall be
mixed thoroughly for uniform coating of aggregates
by bitumen. The mix shall then be transferred to a
500 ml beaker and allowed to cool to room
temperature. Distilled water shall be added in the
beaker, which shall be placed in a water bath
maintained at 400 + l0C for 24 hours. The
percentage degree of stripping shall be assessed
Page 1384 of 1427

Visually. The lest shall also be conducted with water
containing 1 per cent Sodium Chloride, as a
precautionary measure to eliminate water
contamination. The test is repealed using bitumen
containing upto one per cent of antistripping agent in
stages of 0.25 per cent.
TESTING EFFICACY OF ANTISTRIPPING

AGENT TO COAT AGGREGATES WITH
BITUMEN IN PRESENCE OF WATER
Procedure: The antistripping agent shall be

added in per cent contents of 0.0, 0.25, 0.50., 0.75,
1.00 and 1.25 to cutback bitumen MC3 (4pans of
bitumen 80/100 and 1 part of kerosene oil). The
blends shall be used for testing their ability to coat
the road aggregates under water.
(a) 100gm of clean and dry stone dust

conforming to following gradation shall
be taken:
Sieve Size per cent passing

2.36 mm 100
1.18mm 80
600 mic. 75
300 mic. 45
The bottle shall be filled to 3/4 of its volume
with distilled water at 40° C. The bitumen-
antistripping agent blend shall be added in the bottle
at the rate of 7.5 per cent by weight of stone dust.
The stopper shall be replaced and the bottle shall be
Page 1385 of 1427

vigorously shaken for two minutes. The water shall
be then drained off and the stone dust shall be
transferred to a piece of paper and examined visually
for satisfying complete coaling. The minimum per
cent content of anti stripping agent at which the
stone dust sample is thoroughly coated shall be
recorded. The test shall be repeated at 60°C in water
as well as 1 per cent solution of Sodium Chloride in
water for both the testing temperatures.
(b) The under water coating test shall

further be conducted with coarse
aggregate, passing 19 mm sieve and
retained on 13.2 mm sieve. In this case
the per cent content of the cut back-
antistripping agent blend shall be kepi
at 5 per cent by weight of coarse
aggregate. In order to take care of
contamination in water, the ten shall
also be carried out in the 1 per cent
Sodium Chloride in water.
The minimum per cent content of

antistripping agent at which stone dust/coarse
aggregate is thoroughly coated as per (a) and (b)
shall be taken as the dose of antistripping agent
TESTING FOR THERMAL STABILITY OF

ANTISTRIPPING AGENT
Procedure: Blends of antistripping agent and

bitumen of 80/100 grade shall be prepared with 0.00,
Page 1386 of 1427

0.25, 0.50, 0.75 and 1.00 per cent contents of
antistripping agent and kept in oven at 163°Cfor five
hours. After the heat exposure, the blend samples are
fluxed with kerosene oil to obtain the consistency of
MC 3 and tested for under water coaling test.
Reporting of test results: An antistripping

agent shall be deemed to be heat resistant if the dose
requirement before and after heat exposure remains
unchanged.
QUANTITATIVE EVALUATION OF
RETAINED MARSHALL STABILITY VALUES
AFTER IMMERSION IN WATER
Procedure: For quantitative evaluation, the

tests shall be carried out as stipulated in ASTM
D1075 (Effect of Water on Cohesion of Compacted
Bituminous Mixtures). The gradation of aggregates
shall be such as to give sufficient voids ii< the
compacted bituminous mix to bring out the effects of
stripping. The gradation of aggregates shall be as
under:
Sieve Size per cent Passing

19.00 mm 100
13.20mm 75-100
9.50 mm 60-80
4.75 mm 35-55
2.36 mm 20-35
600 mic 10-22
300 mic 6-16
Page 1387 of 1427

150 mic 4-12
75 mic 2-8
The Marshall test specimens shall be
prepared using 5 per cent bitumen of 80/100 grade
by weight of aggregates blended with varying
percentages of antistripping agents from 0 to 1 per
Cent in steps of 0.25 per cent. The test samples shall
give a void content of about 6 per cent. At least 8
standard Marshall specimens for each of the varying
antistripping agent percentages shall be prepared.
Each set of 8 lest specimens shall be sorted out in
two groups of 4 each so that the average specific
gravity of the specimen in group i shall be
essentially the same as in group II. Group-I shall be
tested for Marshall Stability in the usual procedure
ASTM D1559. Group-II specimens shall be
immersed in water for 24 hours at 60°C + 10 C. and
then shall be tested immediately for Marshall
stability as per ASTM D 1559.
Calculation: The numerical index of

resistance of bituminous mixtures to the detrimental
effect of water shall be expressed as the index of
retained stability :
Average Marshall Stability of Group - II

x 100 per cent
Average Marshall Stability of Group - I
Requirement for acceptance: A minimum
Page 1388 of 1427

of 75 per cent of retained Marshall strength shall be
required for acceptance.
Page 1389 of 1427

Appendix 1000-1
DRAFT DOCUMENT ON IS : 9077-1979 CODE

OF PRACTICE FOR CORROSION
PROTECTION OF STEEL REINFORCEMENT
IN RB AND RCC CONSTRUCTION
(REVISED) FOREWORD
This Indian Standard has been revised taking

into consideration the experience gained over the
years, developments those have taken place
subsequently and also considering the need for
evolving suitable acceptance tests for quality control.
In this regard, the electrochemical tests developed at
the Central Electrochemical Research Institute,
Karaikudi, and also the tests specified in
ASTMA775/A775 M-90 for powder epoxy coating
have been considered.
This revised standard supersedes earlier

standard namely 1S:9077-1979. While revising this
standard, it was decided to cover the various test
procedures required to ensure the quality of
individual product as well as the finished products. It
was also decided that this standard should include
very stringent test procedures particularly for
finished products so that these procedures can be
used to evaluate not only the corrosion resistance of
a particular finished product covered by this standard
but also any other finished product such as
galvanising, powder epoxy etc.
Page 1390 of 1427

1. SCOPE
1.1. This standard (revised) specifics the

recommended practice for surface preparation,
surface pretreatment and anti-corrosive treatment
based on inhibited and sealed cement slurry as an in-
sit J process for corrosion protection of mild steel
reinforcement / H YS D bars in conventional
reinforced concrete structures and conventional
reinforced brickwork, constructions. This practice
is also applicable for non-prestressing steels (mild
steel reinforcement/HYSD bars) used in prestressed
Concrete structure.
1.2. This standard applies only for in-situ

corrosion protection of mild steel reinforcement/
HYSD bars after all bending and shaping operations
arc completed. However, this does not preclude the
possibility of using this practice as a factory process.
2. ANTICORROSIVE TREATMENT
PROCESS SEQUENCES
The anticorrosive treatment should

necessarily include the following sequential steps:
(a) Surface preparation (de-rusting)
Since presence of oil, grease, din, heavy scale

and rust will adversely affect the performance of any
anticorrosive treatment, it is essential to adopt
suitable surface preparation technique. Surface
Page 1391 of 1427

preparation can be either by acid pickling or by sand
blasting.
(b) Surface pretreatment
Surface preparation should be immediately

followed by a surface treatment step to ensure
temporary protection during the time lag between the
de-rusting and finish coaling. This pretreatment
should not adversely affect either the adhesion of the
finish coat or corrosion performance.
(c) Inhibited Cement Slurry coating
A minimum of 2 coats should be applied to

ensure full coverage.
(d) Sealing treatment
Sealing treatment should make the coating

harder and less permeable
A typical flow diagram is shown in Fig.

1000/1.
3. PROCEDURE FOR SURFACE

PREPARATION
3.1. Sand Blasting
Sand blasting of the steel surface to SAE 2

1/2 standards can be done
Page 1392 of 1427

3.2. De-rusting by Pickling
The pickling weld should be preferably based

on hydrochloric acid and should include an efficient
inhibitor to prevent base metal attack.
A typical de-rusting solution should have the

following characteristics:
a) inhibitor efficiency should not be less
than 97 per cent.
b) weight loss of a polished standard
mild steel reinforcement / HYSD
bars specimen when dipped in the
solution for 10 minutes should not be
more than 2 g per sq. metre.
c) Specific gravity when tested using a
standard specific gravity bottle should
be around 1.12.
4. PROCEDURE FOR SURFACE PRE-

TREATMENT
De-rusted surface should be immediately

converted by using phosphating treatment. It should
be ensured by a suitable rinsing process that no
residual acid is remaining on the surface at the time
of phosphating. A typical phosphating composition
of brushable consistency should have the following
characteristics :
a) Coating weight when tested ai per test
Page 1393 of 1427

procedure A given hercunder should
be around 4.5 gms/sq.m
b) Density of the product should be in
the range of 1.22 to 1.4 kg/litre.
c) Presence of fungicide shall be tested
by dissolving the jelly in deionized
water, the resulting solution shall be
yellow in colour.
d) Presence of phosphating chemical in
jelly shall be ensured with ammonia
molybdate test
e) pH of the composition when tested in
a standard specific gravity bottle
should be around 2.5 ± 0.1
f) Nail scratch test should clearly leave
a mark on the specimen. This
indicates the existence of the coating.
5. PROCEDURE FOR INHIBITED

CEMENT SCURRY COATING
5.1. A typical inhibitor admixture used

should have the following characteristics:-
(i) It should in liquid form ready for

mixing with the ordinary portland
cement.
(ii) Specific gravity when tested using a
be 1.04 ± 0.02
(iii) pH when tested using a pH meter
should be 12.75 ± 0.25
Page 1394 of 1427

(iv) Tolerable limit for chloride in
inhibitor - admixture when tested
using anodic polarisation technique
(as per test procedure B) should be
300 ± 25 ppm
5.2. Ordinary Portland Cement
This should conform to IS:269 and should be

sieved to pass through 75 microns IS sieve.
Page 1395 of 1427

Page 1396 of 1427
5.3. Cement and inhibitor admixture should
be mixed in specified proportion to have suitable
consistency. Coating should be applied preferably by
brushing. However, under specific circumstances
spraying or dipping is also allowable.
5.4. Sufficient time lag should be allowed in

between successive coatings o ensure final setting of
the undercoat. A minimum of 6 to 12 hours may be
necessary.
5.5. A minimum of two coals with sufficient

lime lag in between should be applied.
6. SEALING TREATMENT
The sealing treatment should be performed

over the coaled surface immediately after final
selling of the top coat. Sealing treatment can be
applied by brushing, spraying or dipping.
6.1. A typical sealing solution should have

the following characteristics:-
(a) Specific gravity when tested using a’

be 1.09 ±0.02
(b) pH when measured using a pH meter
should be-12.25 ± 0.25
(c) Tolerable limit for chloride in sealing
solution using anodic polarisation
Page 1397 of 1427

technique should be 450 ±25 ppm (as
per test procedure B).
7. SPECIFICATIONS FOR FINISHED

END PRODUCT
7.1. Finished coaling when visually

examined should be fairly uniform in thickness and
should be devoid of any defects such as cracks,
pinholes, peeling, bulging etc. No surface area
should be left uncoaled. No rust spot should be
visible to the naked eye.
7.2. Thickness of the Coating
The minimum thickness of the coating shall

be 200 microns. Preferable range is 200 to 400
microns.
7.3. Bond Strength of the Coaled Rebar
The bond strength of the coated rebar and

concrete shall not be less than that specified in
IS:456 as per clause No. 0, 2, 5. II and 44.1.2 and
tested as per IS:2770 (Part 1).
7.4. Hardness of the coaling when measured

using a pencil hardness tester shall be around 5 H to
7 H.
7.5. Tolerable limit for chloride in 0.04

Normal NaOH medium using anodic polarisation
Page 1398 of 1427

technique (as per test procedure B) shall be around
4500 to 5000 ppm.
7.6. No film failure as evidenced by

evolution of hydrogen gas at the cathode or
appearance of corrosion products at the anode shall
take place during one hour of testing (as per test
procedure C).
8. GENERAL REMARKS:
It is advisable that severely rusted and

heavily pined reinforcements are not accepted for
treatment.
TEST PROCEDURE A
Determination of phosphate coaling weight
7.5 cm x 2.5 cm or 7.5 cm x 5 cm mild steel

polished and degreased specimens are to be used for
this lest. First the blank loss of unphosphated
specimen is lo be found out. For this, the initial
weight (W1) is accurately weighed. The specimen is
kept immersed in the Clark’s solution or patented
inhibited de-rusting solution for 1 minute. The
specimen is removed, rinsed in distilled water and
dried using hot air blower. The specimen is
immediately weighed (W2 The difference between
W1 and W2 is termed as blank loss.
Another specimen (polished and degreased)
is brushed with phosphating jelly and kept for 45
minutes. Then the specimen is washed free of jelly,
Page 1399 of 1427

rinsed in clean water and dried using hot air blower.
The phosphated specimen (W3) is accurately
weighed. After weighing, the specimen is kept
immersed in Clark’s solution or patented inhibited
de-rusting solution for one minute. Then the
specimen is removed,.rinsed in distilled water and
dried using hot air blower. The specimen is
immediately weighed (W4). Coating weight = W3 -
W4 - blank loss.
TEST PROCEDURE B
Anodic Polarisation Technique
Mild steel reinforcement / HYSD Bar test

specimens of size 10 mm in dia and 100 mm in
length with stems of size S mm in dia and 50 mm in
length is polished, degreased and sealed at bottom
edge and at the stem with suitable sealers like wax,
lacquer. Then test specimen is kept immersed in test
solution and potential is monitored using high
impedance multimeter against suitable reference
electrode such as saturated calomel electrode/
copper-copper sulphate electrode. After getting
stabilised potential using appropriate current
regulator (0-100 mA), the test specimen is anodically
polarised at a constant current density of 290 µA cm
using a platinum/ stainless steel/ TSIA/ polished
mild steel reinforcement/HYSD Bar as cathode.
Potential with time is followed for 5 minutes after
current is applied. The maximum chloride
concentration upto which the potential remains
Page 1400 of 1427

constant for 5 minutes is taken as a measure of
tolerable limit
TEST PROCEDURE C
Resistance to Applied .Voltage Test
Two mild steel reinforcement / HYSD bars

of size not less than 10 mm in dia and 800 mm in
length shall be given anti-corrosive treatment as per
specified procedure. The end of the rebars shall be
soldered with insulated copper electrical connecting
wire (14 gauge) to serve as electrical contact point
Coated rebars at the two end: shall be sealed with an
insulating material to a length of 25 mm at each end.
Test area shall be the area between the edge of the
bottom sealed end and immersion line which shall
not be less than 250 mm in this case.
The coated rebars shall be suspended

vertically in a non-conductive plastic container of
size not less than 150 mm x 150 mm square and 850
mm high. The rebars shall be so suspended as to
have a clearance of 25 mm at bottom, 45 mm at the
sides and 40 mm in between the rods.
The container shall then be filled to a height

of 800 mm with an aqueous solution of 7 per cent
NaCl. A potential of 2 V in between the coaled rods
shall be impressed for a period of 60 minutes using a
high resistance volt meter for direct current having
an internal resistance of not less than 10 mega Ohms
Page 1401 of 1427

and having a range upto 5V (minimum). Storage
batteries may be used for impressing the voltage.
During this 60 minutes of testing, there shall

not be any coating failure as evidenced by evolution
of hydrogen gas at the cathode or by appearance of
corrosion products of iron at the anode.
Page 1402 of 1427

Appendix-1500/1
INFORMATION TO BE SUPPLIED BY THE

MANUFACTURERS OF PROPRIETARY
SYSTEMS
1. GENERAL
1.1. The information which the manufacturer

is required to supply shall be in such detail as to
obviate unsafe use of the equipment due to the
intention of the manufacturer not having been
made clear or due to wrong assumptions on the pan
of the user.
1.2. The user shall refer unusual

problem or problems of erection/assembly not in
keeping with the intended use of the equipment, to
the manufacturer of the equipment.
2. INFORMATION REQUIRED
2.1. The manufacturers of proprietary

systems shall supply the following information:
a) Description of basic functions of

equipment
b) List of items of equipment available,
giving range of sizes, spans and such
like, with the manufacturer’s
identification numbers or other
references.
Page 1403 of 1427

c) The basis on which the safe
working loads have been
determined and whether the factor of
safety given applies to collapse or
yield.
d) Whether the supplier’s data is
based on calculations or tests.
This shall be clearly stated as
there may be wide variations
between results obtained by either
method.
e) Instructions for use arid maintenance,
including any points which required
special attention during erection,
especially where safely is concerned
f) Detailed dimensional information, as
follows :
i. Overall dimensions and depth
and widths of members,
ii. Line drawings including
perspectives and photographs
showing normal uses,
iii. Self weight.
iv. Full dimensions of
connections and any special
positioning arrangements.
v. Sizes of members, including
tube diameters and
thicknesses of materials,
vi. Any permanent camber built
into the equipment
vii. Sizes of holes and dimensions
Page 1404 of 1427

giving their positions,
g) Data relating to strength of equipment
as follows :
i. Average failure loads a:,
determined by tests.
ii. Recommended maximum
working loads for various
conditions of use.
iii. Working resistance moments
derived from tests,
iv. Working shear capacities
derived from tests.
v. Recommended factors of
safety used in assessing
recommended loads and
deflection based on test
results.
vi. Deflections under load
together with recommended
pre-camber and limiting
deflections.
vii. If working loads depend on
calculations, working stresses
should be staled. If deflections
depend on theoretical
moments of inertia or
equivalent moments of inertia
rather than tests, this should
be noted.
viii. Information on the design of
sway bracing against wind and
other horizontal loadings.
Page 1405 of 1427

ix. Allowable loading relating to
maximum extension of bases
and/or heads.
Page 1406 of 1427

Appendix - 1700/1
SPECIFICATION FOR CONSTRUCTION

JOINTS
Location
The location of construction joints shall be as

shown on the drawing or as approved by the
Engineer. If additional/new joints are approved by
the Engineer, the following considerations for their
location shall be taken into account :
(i) Joints shall be provided in non-

aggressive zones or in non-splash
zones. If not feasible, the joints shall
be sealed.
(ii) Joints should be positioned where
they are readily accessible for
preparation and concreting, such as
location where the cross section is
relatively small, and where
reinforcement is not congested.
(iii) In beams and slabs, joints should not
be near the supports. Construction
joints between slabs and ribs in
composite beams should be avoided.
(iv) For box girders, it is preferable to cast
the soffit and the webs without any
joint.
(v) Location of joints shall minimise the
effects of the discontinuity on the
durability, structural integrity and the
Page 1407 of 1427

appearance of the structure.
Preparation of Surface of the Joint
Laitance shall be removed before fresh

concrete is cast. The surface shall be roughened.
Care shall be taken that they should not dislodge the
coarse aggregates. Concrete may be brushed with a
stiff brush soon after casting while the concrete is
still fresh.
If the concrete has partially hardened, it shall

be treated by wire brushing or with a stiff water jet
followed by drying with air jet immediately.
Fully hardened concrete shall be treated with

mechanical hand tools or grit blasting, taking care
not to split or crack aggregate particles.
Before further concrete is cast, the surface

should be thoroughly cleaned to remove debris and
accumulated rubbish, one effective method being by
air jet.
Where there is likely to be a delay before

placing the next concrete lift, protruding
reinforcement shall be protected. Before the next lift
is placed, rust, loose mortar or other contamination
shall be removed from the reinforcements. In
aggressive environment, the concrete shall be cut
back to expose the reinforcements for a length of
about 50 mm to ensure that contaminated concrete is
Page 1408 of 1427

removed.
The joint surface shall not be contaminated

with release agents, dust or curing membrane.
Concreting of Joints
The old surface shall be thoroughly cleaned

and soaked with water. Standing water shall be
removed shortly before the new concrete is placed
and the new concrete shall be thoroughly compacted.
Concreting shall be carried out continuously upto the
construction joints.
Surface retarders may be used to improve the

quality of construction joints.
For a vertical construction joint, a stopping

board shall be fixed previously at the predetermined
position and shall be properly stayed to prevent its
displacement or bulging when concrete is compacted
against it. Concreting shall be continued right upto
the board.
Page 1409 of 1427

Page 1410 of 1427
Page 1411 of 1427
Appendix - 1800/1
TESTS ON SHEATHING DUCTS
All tests specified below shall be carried out

on the same sample in the order given below.
At least 3 samples for one lot of supply (not

exceeding 7000 metre length) shall be tested.
The tests are applicable for sheathing

transported to site in straight lengths where the
prestressing cable is threaded inside the sheathing
prior to concreting. These tests are not applicable for
sheathing nor for coiled cable and transported to site
as an assembled unit, nor for sheathing ducts placed
in position without threading of prestressing cable
prior to concreting.
(A) WORKABILITY TEST
A test sample 1100 mm long is soldered to a

fixed base plate with a soft solder (Fig. 1800/1-1).
The sample is then bent to a radius of 1800 mm
alternately on either side to complete 3 cycles.
Thereafter, the sealing joints will be visually

inspected to verify that no failure/ opening has taken
place.
(B) TRANSVERSE LOAD RATING

TEST
Page 1412 of 1427

The test ensures that stiffness of the
sheathing is sufficient to prevent permanent
distortion during site handling.
The sample is placed on a horizontal support

500 mm long so that the sample is supported at all
points of outward corrugations.
A load as specified in Table 1 is applied

gradually at the centre of the supported portion
through a contact surface 12 mm long. It shall be
ensured that me load is applied approximately at the
centre of two corrugations. Fig. 1800/1-2. The load
as specified is applied in increments.
TABLE 1
Dia 25- 35- 45- 55- 65- 75- 85-

(mm) 35 45 55 65 75 85 90
Load 250 400 500 600 700 800 1000
(N)
The sample is considered acceptable if the

permanent deformation is less than 5 per cent of the
diameter of the sheathing.
(C) TENSION LOAD TEST
A test specimen is subjected to a tensile load.

The hollow core is filled with a wooden circular
piece having a diameter of 95 per cent of the inner
Page 1413 of 1427

dia of the sample to ensure circular profile during
test loading. Fig. 1800/I-3.
A coupler is screwed on and the sample

loaded in increments, till reaching the load specified
in Table 2. If no deformation of the joints nor
slippage of couplers is noticed, the test shall be
considered satisfactory.
TABLE 2
Dia 25- 35- 45- 55- 65- 75- 85-

(mm) 35 45 55 65 75 85 90
Load 300 500 800 1100 1400 1600 1800
(N)
(D) WATER LOSS TEST
The sample is sealed at one end. The sample

is filled with water and after sealing, the end is
connected to a system capable of applying a pressure
of 0.05 MPa, Fig. 180CV 1-4, and kept constant for
5 minutes using a hand pump with pressure gauge or
stand pipe system can be used.
The sample is acceptable if the water loss

does not exceed 1.5% of the volume.
Page 1414 of 1427

Page 1415 of 1427
Page 1416 of 1427
Page 1417 of 1427
Page 1418 of 1427
Appendix - 18001 III
SPECIFICATIOM FOR GROUTING OF

POST-TENSIONED CABLES IN
PRESTRESSED CONCRETE
1. GENERAL
1.1. The recommendations cover the cement

grouting of post-tensioned tendons of prestressed
concrete members of bridges. This also covers
some of the essential protective measures to be
adopted for minimising corrosion in PSC bridges.
1.2. The purpose of grouting is to provide

permanent protection to the post-tensioned steel
against corrosion and to develop bond between the
prestressing steel and the surrounding structural
concrete. The grout ensures encasement of steel in
an alkaline environment for corrosion protection
and by filling the duct space, it prevents water
collection and freezing.
2. MATERIALS
2.1. Water
Only clean potable water free from impurities

conforming to section 1000 shall be permitted. No
sea or creek water is to be- used at all.
2.2. Cement
Page 1419 of 1427

Ordinary Portland cement should be used for
preparation of the grouT. It should be as fresh as
possible and free of any lumps. Pozzolana cement
shall not be used.
23. Sand
It is not recommended to use sand for

grouting of prestressing tendons. In case the internal
diameter of the ducts exceeds 150 mm, use of sand
may be considered. Sand, used, shall conform to
IS:383 and shall pass through IS Sieve No. 150. The
weight of sand in the grout shall not be more than 10
per cent of the weight of cement, unless proper
workability can be ensured by addition of suitable
plasticizers.
2.4. Admixtures
Acceptable admixtures conforming to

IS:9102 may be used if tests have shown that their
use improves the properties of grout, i.e. increasing
fluidity, reducing bleeding, entraining air or
expanding the grout. Admixtures must not contain
chlorides, nitrates, sulphides, sulphites or any otherr
products which are likely to damage the steel or
grout. When an expanding agent is used, the total
unrestrained expansion should not exceed 10 per
cent. Aluminum powder as an expanding agent is not
recommended for grouting because its long term
effects are not free from doubt.
Page 1420 of 1427

2.5. Sheathing
2.5.1. For specifications of sheathing, section

1800 may be referred
2.5.2. Grout openings or vents
i) All ducts should have grout openings at

both ends. For this purpose special
openings should be provided where
such openings are not available at
end anchorages. For draped (curved)
cables vents shall be provided at all
crown and valley points. It is a good
practice to provide additional air
vents at suitable intervals not
exceeding 20 m. All grout openings
or vents should include provisions for
preventing grout leakage.
ii) Standard details of fixing couplers,
inlets, outlets and air vents to the
duel/ anchorage shall be followed as
recommended by the supplier of the
prestressing system.
2.5.3. Ducts should be securely fastened at

close intervals. All unintended holes or openings in
the duct must be repaired prior to concrete placing.
The joints of the couplers and the sheathing should
be made water proof by use of adhesive tape or
similar suitable system capable of giving leak proof
Page 1421 of 1427

joints. Grout openings and vents must be securely
anchored to the duct and to either the forms or to
reinforcing steel to prevent displacement during
concreting operations due to weight, buoyancy and
vibrations.
2.5.4. Ducts require very careful handling

as, being of thin metal, they are susceptible to
leakage due to corrosion in transit 01 storage, by
tearing/ripping in handling particularly when
placed adjoining to reinforcing steel, by pulling apart
at joints while inserting tendons prior to
concreting, or by accidental puncturing while
drilling for form ties/inserts. Ducts are also liable to
damage by rough use of internal vibrator and sparks
from welding being done close by.
3. EQUIPMENT
3.1. Grout Mixer and Agitator
It is essential that the grout is maintained in a

homogeneous state and of uniform consistency so
that there is no separation of cement. Use of grout
mixers to obtain a colloidal grout is essential. The
mixer should have an additional storage device with
an agitator to keep the grout moving continuously
before it is pumped in the duct. Positive
reciprocating type grout pumps should be used.
3.2. Grout Pump
Page 1422 of 1427

The pump should be a positive displacement
type and should be capable of ejecting the grout in a
continuous operation and not by way of pulses. The
grout pump must be fitted with a pressure gauge to
enable pressure of injection to be controlled. The
minimum pressure at which grout should be pumped
shall be 0.3 MPa and the grout pump must have a
relief arrangement for bypass of the grout in case of
build up of pressure beyond 1 MPa. The capacity of
the grout pump should be such as to achieve forward
speed of grout of around 5 to 10 metres per minute.
The slower rates are referable as they reduce the
possibility of occurrence of voids. If the capacity of
the pump is large, it is usual to grout two or more
cables simultaneously through a common manifold.
Use of hand pumps for grouting, is not

recommended. Use of compressed air operated
equipment for injection is prohibited, as it is likely
that there will be some air trapped in grout.
3.3. Water Pump
Before commencement of grouting, a stand

by direct feed high pressure water pump should be
available at site for an emergency. In case of any
problem in grouting the ducts, such pump shall
immediately be connected to the duct and all grout
flushed by use of high pressure water flushing. It is,
therefore, necessary to have adequate storage of
clean potable water for operation of the water pump
for such emergencies.
Page 1423 of 1427

3.4. Grout Screen
The grouting equipment should contain a

screen having a mesh size of 106 micron size of 150
microns if sand is used). Prior to introduction into
the grout pump, the grout should be passed through
such screen. This screen should be easily accessible
for inspection and cleaning.
3.5. Connections and Air Vents
Standard details of fixing inlets, outlets and

air vents to the sheathing and/ or anchorage should
be followed as recommended by specialist supplier
of the system of prestressing. In general, all
connections are to be of the “Quick couple” type and
at change of diameters suitable reducers are to be
provided.
4. PROPERTIES OF THE GROUT
4.1. Water/cement ratio should be as low as

possible, consistent with workability. This ratio
should not normally exceed 0.45.
4.2. Before grouting, the properties of the

grout mix should be tested in a laboratory depending
on the facilities available. Tests should be conducted
for each job periodically. The recommended test is
described below.
Page 1424 of 1427

4.3. Compressive Strength The compressive
strength of 100 mm cubes of the grout shall not be
less than 17 MPa at 7 days. Cubes shall be cured in a
moist atmosphere for the first 24 hours and
subsequently in water. These tests shall be conducted
in advance to ascertain the suitability of the grout
mix.
5. MIXING OF GROUT
5.1. Proportions of materials should be based

on field trials made on the grout before
commencement of grouting, but subject to the limits
specified above. The materials should be measured
by weight.
5.2. Water should be added to the mixer,

first, followed by Portland cement and sand, if
used. Admixture if any, may be added as
recommended by the manufacturer.
5.3. Mixing time depends upon the type of

the mixer, but will normally be between 2 and 3
minutes. However, mixing should be for such a
duration as to obtain uniform and thoroughly
blended grout, without excessive temperature
increase or loss of expansive properties of the
admixtures. The grout should be continuously
agitated until it is injected.
5.4. Once mixed, no water shall be added to

the grout to increase its fluidity.
Page 1425 of 1427

5.5. Hand mixing is not permitted.
6. GROUTING OPERATIONS
6.1. General
a) Grouting shall be carried out

as early as possible but not
later than 2 weeks of stressing
a tendon Whenever this
stipulation cannot be complied
with for unavoidable reasons,
adequate temporary protection
of the steel against corrosion
by methods or products which
will not impair the ultimate
adherence of the injected
grout should be ensured till
grouting. The scaling of the
anchorage ends after
concreting is considered to be
a good practice to prevent
ingress of water. For
structures in aggressive
environment, sealing of the
anchorage ends is mandatory.
Notes :
i) Application of some patented water soluble

oils for coating of steel/VPI powder
Page 1426 of 1427

injection/ sending in of hot, dry, oil-free
compressed air through the vents at frequent
intervals have shown some good results.
ii) Some of the methods recommended for
sealing of anchorages are lo seal the openings
with bitumen impregnated gunny bag or
water proof paper or by building a brick
pedestal plastered on all faces enclosing the
exposed wires outside the anchorages.
iii) Any traces of oil if applied to steel for
preventing corrosion should be removed
before grouting operation.
iv) Ducts shall be flushed with water for
cleaning as well as for welling the surfaces of
the duct walls. Water used for flushing
should be of same quality as used for
grouting. It may, however, contain about 1
per cent of slaked lime or quick lime. All
water should be drained thorough the lowest
vent pipe or by blowing compressed air
through the duct
v) The water in the duct should be blown out
with oil free compressed air.
Blowing out water from duct for cables

longer than SO m draped up at both ends by
compressed air is not effective, outlet/ vent
provided at or near the lowest point shall be
used to drain out water from duct
vi) The connection between the nozzle of the
injection pipe and duct should be such that
air cannot be sucked in.
Page 1427 of 1427

vii) All outlet points including vent openings
should be kept open prior to commencement
of. injection grout
viii) Before grouting, all air in the pump and hose
should be expelled. The suction circuit of the
pump should be air-light
6.2. Injection of Grout
a. After mixing the grout should be

kepi in continuous movement
b. Injection of grout must be continuous
and should not be interrupted.
c. For vertical cable or cables inclined
more than 60 degrees to the
horizontal, injection should be
effected from the lowest anchorage
or vent of the duct
d. The method of injection should
ensure complete filling cf the duels.
To verify this, it is advisable to
compare the volume of the space to
be filled by the injected grout with the
quantity of grout actually injected.
e. Grouting should be commenced
initially with a low pressure of
injection of upto 0.3 MPa increasing
it until the grout comes out at the
other end. The grout should be
allowed to flow freely from the other
end until the consistency of the grout
at this end is the same as that of the
Page 1428 of 1428

grout at the injection end. When the
grout flows at the other end, it should
be closed off and building up of
pressure commenced. Full injection
pressure at about O.S MPa shall be
maintained for at least one minute
before closing the injection pipe. It is
recommended practice to provide a
stand pipe at the highest point of the
tendon profile to hold all water
displaced by sedimentation or
bleeding. If there is a built up of
pressure much in excess of 1 MPa
without flow of grout coming al the
other end, the grouting operation
should be discontinued and the entire
duct flushed with high pressure water.
Also, the bypass system indicated in
para 3.2 above is essential for further
safety.
f. In the case of cables draped
downwards e.g. in cantilever
construction simultaneous injection
from both ends may be adopted Fig.
1300/111-1.
g. Grout not used within 30 minutes of
mixing should be rejected.
h. Disconnection is facilitated if a short
length of flexible lube connects the
duct and injection pipe. This can be
squeezed and cut off after the grout
has hardened.
Page 1429 of 1429

7. PRECAUTIONS AND
RECOMMENDATIONS FOR EFFECTIVE
GROUTING
a) In cold and frosty weather, injection
should be postponed, unless special
precautions are taken. If frost is
likely to occur within 48 hours after
injection, heat must be applied to
the member and maintained for at
least 48 hours after injection so that
the temperature of the grout does
not fall below 5 degrees Celsius.
Prior to commencement of grouting,
care must be taken to ensure that the
duct is completely free of frost/ice
by flushing with warm water, but not
with steam.
b) The temperature of the grout shall not
exceed 25 degrees Celsius. For
increasing the workability of grout, its
temperature may be lowered by use of
chilled water or by putting ice
outside the grout storage container.
c) When the cables are threaded after
concreting, the duct must be
temporarily stiffened during
concreting by inserting bunch of
strands, wires or reinforcement or a
rigid PVC pipe or any other suitable
method.
d) During concreting, care shall be taken
Page 1430 of 1430

to ensure that the sheathing is not
damaged. Needle vibrators shall be
used with extreme care by well
Page 1431 of 1431

Page 1432 of 1432
experienced staff only, to ensure against such
damage.
e) It is a good practice to move the
cables in both directions during the
concreting operations. This can
easily be done by light hammering
the ends of the wires/ strands during
concreting. It is also advisable that 3
to 4 hours after concreting the cable
should be moved both ways through
a distance of about 20 cms. With
such movement, any leakage of
mortar which has taken place in spite
of all precautions loses bond with die
cables, thus reducing the chance of
blockages. This operation can also be
done by fixing prestressing jacks, at
one end pulling the entire cable and
then repeating the operation by fixing
the jack at the other end.
f) The cables to be grouted should be
separated by as much distance as
possible.
g) In case of stage prestressing, cables
tensioned in the first stage should not
remain ungrouted till all cables are
stressed. It is good practice, while
grouting .any duct in stage
prestressing, to keep all the remaining
ducts filled up with water containing
1 per cent lime or by running water
through such ducts till the grout has
Page 1433 of 1433

set. After grouting the particular
cable, the water in the other cables
should be drained and removed
with compressed air to prevent
corrosion.
h) Care should be taken to avoid leaks
from one duct to another at joints of
precast members in particular.
i) End faces where anchorages are
located are vulnerable points of entry
of water. They have 10 be necessarily
protected with an effective barrier.
Recesses should be packed with
mortar concrete and should preferably
be painted with water proof paint.
j) After grouting is completed, the
projecting portion of the vents should
be cut off and the face protected to
prevent corrosion.
Page 1434 of 1434

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Ministry of Road Tr

Printed at Dee Kay Printers, New Delhi - 110 015

This edition of Specifications for Road &

These Specifications shall apply to all such

The words like Contract, Contractor,

The following abbreviations shall have the

AASHTO : American Association of Slate

The various elements in the cross-section of a

103. MATERIALS AND TEST STANDARDS

The relevant standards for materials, as well

104. SIEVE DESIGNATIONS

The sieve designations referred to in the

TABLE 100-1. DESIGNATION OF TEST

105. SCOPE OP WORK

105.1. The work to be carried out under the

105.2. The works to be performed shall also

105.3. The Contractor shall ensure that all

105.4. The Contractor shall furnish, at least

106. CONSTRUCTION EQUIPMENT

In addition to the general conditions

107. CONTRACT DRAWINGS

107.1. The Contract Drawings provided for

107.2. The tendered rates/prices for the work

107.3. Two copies of drawings, on the basis

107.4. Examination and /or approval by the

108.1. The information about the site of

108.2. The location of the works and the

108.3. Whereas the right-of-way to the

108.4. The quarry charts enclosed with the

109. SETTING OUT

109.2. The lines and levels of formation,

109.3. In order to facilitate the setting out of

109.4. On construction reaching the

109.5. No reference peg or marker shall be

109.6. The Contractor will Be the sole

109.7. After obtaining approval of the

109.8. The work of setting out shall be

109.9. Precision automatic levels, having a

110.1. Drawings scheduling the affected

110.2. Notwithstanding the fact that the

110.3. No clearance or alterations to the

110.4. Any services affected by the Works

110.6. The work of temporarily supporting

110.7. The Contractor may be required to

111. PRECAUTIONS FOR SAFEGUARDING

The Contractor shall take all precautions for

Borrowpits shall not be dug in the right-of-

The Contractor shall obtain materials from

111.4. Control of Soil Erosion,

The Contractor shall carry out the works in

111.5. Pollution from Hot-Mix Plants and

Bituminous hot-mix plants and concrete

111.6. Substances Hazardous to Health

111.7. Use of Nuclear Gauges

Nuclear gauges shall be used only where

111.8. The Contractor must take all

111.9. All existing highways and roads

111.12. Compliance with the foregoing will

112. ARRANGEMENT FOR TRAFFIC

The Contractor shall at all limes carry out

112.2. Passage of Traffic along a part of

112.3. Passage of Traffic along a