Construction Methodology

CLIENT: NATIONAL HIGHWAYS AUTHORITY OF INDIA QUALITY MANAGEMENT SYSTEM
Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

0.000 to km 43.800 on Hybrid Annuity Mode under Bharatmala REV. No.:01
Pariyojana, in the state of Andhra Pradesh and Tamil Nadu
REV. Date : 06.02.2023
(Package-I).
CONCESSIONAIR: KCC CHITTOOR HIGHWAYS PVT INDEPENDENT ENGINEER: MSV INTERNATIONAL
LTD. INC. JV ARMENGE
1 06 Feb 2023
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01 INTRODUCTION 5
02 SITE CLEARANCE(CLEARING&GRUBBING/DISMANTALING) 6-7
03 SURVEY WORKS 8-10
04 ROADWAY EXCAVATION OF UNSUITABLE MATERIAL / MARSH SOIL 11-12
06 ROADWAY EXCAVATION OF SUITABLE MATERIAL 13-15
07 EMBANKMENT / SUBGRADE FROM BORROW AREA / EXCAVATED SUITABLE SOIL 16-18
08 GRANULAR SUB BASE 19-20
09 WET MIX MACADAM 21-22
10 PRIME COAT 23-24
11 TACK COAT 25
12 DENCE BITUMINOUS MACADAM 26-29
13 BITUMINOUS CONCRETE / AC WEARING COURSE 30-33
14 STONE MATRIX ASPHALT 34-37
15 BITUMEN MASTIC 38-39
16 CEMENT CONCRETE KERB 40-41
17 DRY LEAN CONCRETE 42-45
18 PAVEMENT QUALITY CONCRETE 46-52
20 STONE MASONRY 53-54
21 SHOULDERS / MEDIANS / ISLAND 55-56
22 SLOPE PROTECTION WORKS (SLOPE PITCHING) IN HIGH EMBANKMENTS 57-58
23 REINFORCED CONCRETE PIPE CULVERT 59-60
24 OPEN EXCAVATION 61-62
25 CONCRETE WORKS 63-66
26 REINFORCEMENT STEEL 67-68
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27 FOUNDATION / SUB STRUCTURE 69-71

28 BOARD ENCASED PILE FOUNDATION 72-78
30 SUPER STRUCTURE 79-80
31 PRE-STRESSING OF STEEL CABLE IN BRIDGE GIRDERS 81-83
32 EXPANSION JOINTS 84
33 TURFING 85
34 ROAD MARKING 86
35 CTSB/CTB 87-88
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INTRODUCTION
The National Highways Authority of India has awarded the work of “ Development of Six Lane Chittoor-
Thatchur Highway from km 0.000 to km 43.800 on Hybrid Annuity Mode under Bharatmala Pariyojana,
in the state of Andhra Pradesh and Tamil Nadu (Package-I).”. to EPC Contractor M/s KCC Buildcon Pvt.
Ltd.
This Construction Methodology including required materials, equipment’s involvement & Construction process
prepared for construct “ Development of Six Lane Chittoor-Thatchur Highway from km 0.000 to km
43.800 on Hybrid Annuity Mode under Bharatmala Pariyojana, in the state of Andhra Pradesh and
Tamil Nadu (Package-I).”. Inspection & Test Plan already described in Quality Assurance Plan.
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1.0 DESCRIPTION
The scope of the work and other requirements under site clearances shall be as per MORT&H clauses 201
and 202, which include removal and disposal of top organic soil up to 150 mm thickness. On completion of
site clearance, testing for Soil suitability shall be carried out.
2.0 MATERIALS
The Use of top soil obtained from clearing and grubbing shall be decided after relevant test result.
3.0 EQUIPMENT
a) Site Clearing works are to be carried out using the following equipment’s or any combination that
is applicable.
i. Dozer/Grader.
ii. Hydraulic Excavator/Back hoe loader.
iii. Frontend loader.
iv. Tipper / Trucks.
b) Structures that cannot practicably be cleared by hydraulic excavators and/or dozers, then these
demolitions will be carried out using pneumatic tools, explosives and/or other specialized
equipment depending on the size and type of structures. Before commencing demolition using
explosive required, all necessary permits and licenses will be obtained and a blasting plan and
safety precaution will be prepared before commencement of blasting works.
4.0 CONSTRUCTION PROCEDURE

Site clearance procedure shall consist, the following activities either independently or jointly with the
Independent Engineer’s Representative as per guidelines.
a) The right of ways (ROW) be surveyed and set out according to the data stated in the
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drawings.
b) To determine whether site is free from obstruction and in case of nonconformity, photographs shall
be taken of structures, landscaping, trees and shrubs, fences, telephone and electrical poles and
other so-called obstructions as are payable under individual measured items apart from the
general site clearance in the bill of quantities.
c) Prior to demolition of existing buildings we shall liaise with the respective authorities to
terminate/divert the utilities as required by the concerned authorities as per clause 110.7.
d) Removal of landscaping trees shall be carried out in consultation with the Independent Engineer’s
representative and prior approval of the concerned authority.
e) Fencings or others that are to be relocated or salvaged shall be carried out according to the
Drawings.
f) Obtain confirmation that the right of way lands have been acquired by the Employer or relevant
authorities, (Hand over from Authority).
g) Access roads to the site shall be constructed if required enable vehicles, equipment’s and plants
to be brought into the site.
h) Solid waste dumps sites shall be predetermined within or outside the site for the dumping of the
site clearing materials as advised by the Client.
i) The site clearance team shall then proceed to clear the trees, vegetation, undergrowth, bushes
and minor structures by hydraulic excavators or back hoe loader and or manually.
j) All unwanted materials shall be piled up and disposed off in a tidy manner at the designated
dumping areas.
k) Material directed by the Engineer to be salvaged, shall be removed and stored within the Right of
Way and shall be the property of the Employer or the Government whichever is specified in the
contract.
l) Excavation/Backfilling resulting from uprooting of trees and stumps shall be done with suitable soil
to the required compaction.
m) Joint survey of existing ground level shall be carried out. In case joint survey is not feasible,
independent survey shall be carried out by the Contractor and subsequently approval of Client
shall be obtained.
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1.0 DESCRIPTION
The scope of the work and other requirements under site shall be establishment of working Benchmarks tied
with the reference benchmarks in the area after taking possession of the site which includes lines, levels of
formation side slopes, drainage works, structures, carriageways and shoulders shall be carefully set out and
frequently checking as per MoRT&H clauses 109.
2.0 EQUIPMENT
i) GPS System
ii) Total Station
iii) Auto level
3.0 PROCEDURE
3.1 Initial Survey
The survey is being done as per the following methodology. Initially a network of ground control points has
been established at every 250 meter and these points have been connected to the DGPS network.
3.1.1 DGPS
Differential Global Positioning System has been developed to rectify and correct the errors in an ordinary
GPS. Since the DGPS hardware at the station already knows its own position, it can easily calculate its
receiver’s in accuracy. The station then broadcasts a radio signal to all DGPS–equipped in the area,
providing signal correction information for that area. In general, access to this correction in formation makes
DGPS receivers much more accurate than ordinary receivers. The most essential function of a DGPS
receiver to pick up the transmission so that at least four satellites and combined the information in those
transmissions with information in an electronic almanac, all in order to figure out the receiver’s position on
Earth. Once receivers make these calculations, it can tell us the Latitude (Northing), Longitude (Easting) and
Altitude (Zonal Elevation) of its current Location with reference to True North. This operation is based on a
simple mathematical principle called tri late ration.
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A pair of DGPS points at every 5kms a part are observed from a constellation of Earth-0rbitings satellites and
fixed the Base, North Bearing and Graph of the terrain as datum to this project. In between GPS pillars at
every 250 mts interval, along the road alignment, the sub control pillar [Temporary Bench Mark Pillar (TBM)]
is fixed at the end of ROW (Right Of Way) or wherever required. The location of bench mark pillar is marked
at site by paint identifying location. Benchmark pillars are concrete pillars. During the time of traversing the
bearing was recorded on the punch point of rod projected over the benchmark pillar. The coordinate value of
each benchmark pillar was arrived after traverse adjustment by Bow-ditch method.
3.1.2 TRAVERSE
By measuring Horizontal angle between two straights, by measuring horizontal distance between two points
and by measuring height deference of two points a traverse line will be carried out from fixed known points
and closed on known points. This will be called as “Closed Circuit Traverse”. By calculating its co-
ordinates (X,Y,Z) whole to the part the mis closures can be traced out and distributed to maintain its required
accuracy. The traverse accuracy is maintained between 1:5000 and 1:15000m.as the traverse carried out
through heavy traffic.
The above procedure will carry out every month for Crosschecking. If any error occurs that will be
reconfirming and distributed in between DGPS.
3.2 Detailed Survey

With reference of Base and Bearing (North) of these traverse points as trip of Topographic Survey will be
carried out to depict existing details and features such as median, Bituminous edge, shoulder, toe of existing
carriageway and the limits of ROW. Also, the details of existing utilities and service roads and structures are
taken with a Total Station in the form of code & coordinates. With built in program all the details will be stored
directly to the concerned job files created in Total Station. The data can be down loaded into a system and
transferred to required format to reproduce 3-D drawings. The observed data may be edited and corrected if
require.
3.2.1 REFERENCE LINE

With the reference of Detailed Survey data received from site, the observations will be made on construction
of structures, giving importance for historical monuments, available corridor in built up areas, deviation of
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existing carriageways a reference line is fixed as per the IRC Codes for design of Horizontal alignment. The
designed alignment coordinates at every 10m interval are sent back to site. The designed coordinates will
be up loaded into Total Station a n d the line of alignment will be laid out on the ground by marking its
location.
3.2.2 ORIGINAL GROUND LEVEL

With reference to laid out reference line in the site the original ground levels will be staked in with an auto
level survey instrument. The levels are observed at 10m. Interval along the longitudinal line with prescribed
offsets on cross section. The curve portions will be staked in at 5m. Interval and the undulating terrain will
be observed on closer offsets.
3.2.3 SURVEY FOR STRUCTURE

Apart from the above, detailed survey is also done at all structure and CD works locations. This information is
used while designing the structures/CD works. The points where the Bore log details are to be taken are also
set out by the survey team in coordination with the Materials section. One team is deployed with total stations
for this survey.
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1.0 DESCRIPTION
Removal of unsuitable materials defined/ specified in Technical Specification or MoRT&H guide line
either in roadway cutting or filling area.
2.0 MATERIALS
Samples after clearing and grubbing shall be taken and tested for laboratory parameter determinations,
so that it may be classified as suitable or not suitable for the various categories of fill with all results given
to client to decide the use of soil.
2.1 If the material is having following properties, then theses soils shall be treated as an unsuitable soil.
2.1.1 The materials from Swamps, marshes and bogs,
2.1.2 The materials classifies as OL (organic silt and clays of low plastic), OI (organic
silt and clays of medium plastic), OH (organic silt and clays of high plastic) or Pt
in accordance with IS:1498
2.1.3 The materials susceptible to spontaneous combustion,
2.1.4 The materials in a frozen Condition,
2.1.5 The material shall be greater than 50 Liquid Limit and plasticity Index greater than 25,
2.1.6 The material shall be greater than 50% Free swell Index,
2.2 The density of material according to MoRT&H Table300–1 i.e.
a) For embankment layers, Embankment up to 3m height, not subjected to extensive flooding,
the soil maximum laboratory dry density not less than1.52gm/cc
b) For embankment layers, Embankment exceeding 3m height or embankments of any height
subject to long periods of inundation, the soil maximum laboratory dry density not less
than1.60gm/cc
c) For subgrade and earthen shoulders / verges / back fill the soil maximum laboratory dry density
not less than1.75gm/cc
2.3 If the material CBR value is less than design CBR value, then the soil unsuitable for Subgrade.
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3.0 EQUIPMENTS
i) Excavator
ii) Tipper trucks/Tractors
iii) Dozer
iv) Grader
v) Plate compactor
vi) Earth compactor
4.0 CONSTRUCTIION PROCEDURE

a) Extent of unsuitable materials area shall be identified after testing, and then it will be on the depth of
excavation to be determined by trial pits taken for sampling and test results. Existing ground level are
to be jointly surveyed and agreed prior to excavation. Excavated unsuitable material will be
deposited at designated dumping ground. RFI will be submitted before excavation commences.
b) Excavation of marshes shall begin at one end and proceeding in one direction, across the entire
marsh will be removed, and immediately back filling shall be done in layer 250 mm compacted
thickness with boulders or granular material or sand otherwise dismantled concrete. The spreading
will be done with tracked dozer or grader or front blade tractor or manually as per site condition. The
compaction will be done with tracked dozer or earth compactor or plate compactor.
c) If back fill material boulder or dismantled concrete is used, 500mm thick earthen cushion will be
maintained over the boulder or Dismantled Concrete.
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1.0 DESCRIPTION
The work consists of excavation and disposal of all materials to embankment or sub grade construction
or to spoil if it is surplus and finishing the cut area to line and dimension as specified in the drawing.
2.0 MATERIAL
If the material is having following properties, then these soils shall be treated as suitable soil.
2.1.1 The materials free from Swamps, marshes and bogs,
2.1.2 The materials classifies as OL (organic silt and clays of low plastic), OI (organic
silt and clays of medium plastic), OH (organic silt and clays of high plastic) or Pt
in accordance with IS:1498
2.1.3 The materials free from susceptible to spontaneous,
2.1.4 The materials free from in a frozen Condition,
2.1.5 The material shall have less than 50% Liquid Limit and plasticity Index shall be less than 25,
2.1.6 The material shall have less than 50% Free swell Index,
2.1.7 The density of material according to technical specification Table 300 – 1 i.e .
a) For embankment height up to 3.0 meters > 1.52 grams/cc
b) For embankment height exceeding 3.0 meters > 1.60 grams/cc.
2.1.8. For sub-grade and earthen shoulders > 1.75 grams/cc.
2.1.9. For subgrade suitability, the material shall have CBR value of not less than designed value.
3.0 EQUIPMENT
a) Excavator/Loader
b) Tipper Trucks/Tractors
c) Motor grader.
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a) Excavation: The material shall be excavated after testing to the required level or as shown in the
cross section.
b) Prior to commencement of the work, surveyor shall use the survey data of road alignment and
TBM provided by the Authority for setting out the extent of cutting in accordance with the cross
sections and establish reference markers at suitable intervals and locations necessary to control
the work.
c) All the major setting out works shall be carried out jointly with the Independent Engineer’s
Surveyor. However, if joint setting out is not possible the independent setout shall be checked
by the IE.
d) Before commencement of cut, it shall be ensured that the haul roads are having sufficient width
for passing traffic and for smooth movement of the equipment. The diversion of traffic, warning
signs and flagmen will be provided wherever necessary. Special care shall be taken for safety
measures during night as per the contract.
e) The excavation shall be started from the top of the high ground down to the formation levels. If
any change of material is observed, the IE will be notified and the material will be jointly checked
and if necessary sampling and testing shall be done for continued suitability of use. If the
changed material encountered is rock then the same shall be notified for classification with
RFI. If unsuitable material as per clause 305.2.1.1 is encountered then it will be jointly recorded
with the IE and disposed of as instructed.
f) Slopes in cutting shall be trimmed mechanically to neat and even surfaces in accordance
with the designed gradients.
g) On fill slopes, the filling shall be done in layers with extended width to allow cut back to
form the slope in compacted material.
h) The slope trimming shall be completed after the pavement and shoulders are completed. The
trimmed slope is to be turfed if specified.
i) Engineering stage checks shall be jointly carried out and recorded at the top of Embankment
Fill and top of Formation/Sub grade levels.
j) The construction of side drain shall follow closely to the slope trimming and surface water shall
be regulated to discharge to the side drain.
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5.0 QUALITY CONTROL

Routine testing to be carried out as stipulated within MoRT&H section 900 and conforms to
specifications.
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1.0 DESCRIPTION
The work involves construction of embankment/subgrade as per clause 305 of MoRT&H up to subgrade top
layer with approved materials obtained from borrow pits or roadway excavation or other sources to the
lines, levels, grades, cross section shown on the drawings.
2.0 MATERIALS
The physical properties of Materials for Embankment and Sub- grade,
2.1.1 The materials free from Swamps, marshes and bogs,
2.1.2 The materials classifies as OL (organic silt and clays of low plastic), OI (organic silt and
clays of medium plastic), OH (organic silt and clays of high plastic) or Pt in accordance
with IS:1498
2.1.3 The materials free from susceptible to spontaneous,
2.1.4 The materials free from in a frozen Condition,
2.1.5 The material shall have less than 50% Liquid Limit and plasticity Index shall be less than 25,
2.1.6 The material shall be less than 50% Free swell Index,
2.1.7 The density of material according to technical specification Table 300 – 1 i.e.
a) For embankment height up to 3.0 meters > 1.52 grams/cc
b) For embankment height exceeding 3.0 meters > 1.60 grams/cc.
2.1.8 For sub-grade and earthen shoulders > 1.75 grams/cc.
2.1.9 For subgrade suitability, the material shall have CBR value of not less than designed value.
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3.0 EQUIPMENT
a) Excavator
b) Tipper trucks
c) Motor grader
d) Vibratory roller (80 KN to 100 KN static weight)
e) Water Tankers with sprinkler.

a) Ground preparation: The original ground or excavated ground level shall be loosened up to depth
of suitable (for compacted layer thickness 250mm) and leveled sprinkled water and then compacted
with vibratory roller of 80 KN to 100 KN in static weight to facilitate placement of first layer of
embankment.
b) After final rolling is over, the RFI shall be raised to check the compaction level i.e. 95% of the
laboratory density and for level recording jointly.
c) Filling and spreading shall be carried out in uniform layer of 250mm to give a compacted
thickness of not more than 250mm per layer over the entire width of Embankment/Sub- grade.
Materials shall be tipped from dump trucks and spread to the required thickness using motor
grader or tractor blade. The motor grader blade shall be adjusted initially and maintained the same
so as to achieve the specific slope and grade. Where it is the intention to commence filling on
ground that has a steep transverse slope, filling will be preceded by cutting tie-ins to firm material
for cross fill. Trial compaction shall be carried out at the site to determine the pattern of
compaction for material to be used. This shall indicate the use of compaction equipment and
number of passes in relation to the loose depth of material to achieve desired compaction.
d) Moisture content of each layer of soil shall be checked before compaction and moisture content
will be maintained -2% to +1% of the OMC.
e) If moisture content is less than the required level, the water will be sprinkled with the help of
controlled rate of flow of water tanker sprinkler. After sprinkled the water the embankment or sub-
grade material shall be thoroughly mixed by blading or harrowing until uniform moisture content is
obtained throughout the depth of the layer.
f) If moisture content is more than the required level, the material shall be dried by expose to air and
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expose to sun.
g) Field Density tests to be conducted as per specification i.e 95% of MDD for Embankment Fill
and 97% of MDD for sub grade layers.
h) On fill slopes, the filling shall be in layers with extended width to allow cut back to form the slope
in compacted material.
i) The slope trimming shall be completed after the pavement and shoulders are completed. The
trimmed slope is to be turfed if provided.
j) Engineering stage level checks shall be jointly carried out and recorded at the top of
Embankment Fill and top of Formation/ top of Sub grade levels.
5.0 QUALITY CONTROL

specifications.
6.0 INSPECTION AND TEST PLAN

6.1 Original Ground level: The Level and density checking to be recorded jointly.
6.2 Filling layers:
6.1.1 Each fill layer to be reported and density test will be checked.
6.1.2 Final layer: levels to be reported and density check.
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1.0 DESCRIPTION
The work consists of laying and compacting approved graded sub base materials on approved sub
grade as per clause 401 of the specification after appropriate trial(s).
2.0 MATERIALS
The materials will be approved Natural sand, crushed gravel, crushed stone, crushed slag or
combination thereof complying with clause 401.2
3.0 EQUIPMENT
a) Front Loader
b) Tipper Trucks
c) Motor grader
d) Water Tankers
e) Vibrator roller (8OKN to 1OOKN Static weight)
4.0 CONSTRUCTION PROCUDURES

a) The sub base materials are produced from approved sources or crushed or blended material to
satisfy grading requirements etc.
b) Prior to commencement of operations the underlying layer is to be approved and inspected.
c) Level pegs/markers to be established for trimming control to the specified tolerance. Established
pegs from sub grade layer can be used.
d) Sub base material to be tipped directly on approved underlying layer and spreading and leveling
to be done with motor grader. Water will be added to raise moisture content as required to OMC
values.
e) Compaction with vibratory roller to be carried out until surface is free from movement, ridges,
cracks or loose material and material achieves minimum of 98% of MDD.
f) Field density test to be carried out to ensure compaction compliance as per specifications.
5.0 RECTIFICATION OF SURFACE IRREGULARITIES

These shall be carried out as stipulated within MoRT&H clauses 401.4 and 902.
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6.0 QUALITY CONTROL

Routine testing to be carried out as stipulated within MoRT&H Section 900.
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1.0 DESCRIPTION
This Method Statement outlines the procedure for the production and laying of AIL/WMM as per
MoRT&H clause 406 after appropriate trials and the appropriate drawings. As per Pavement Design AIL
thickness are 100mm. for Main Carriage Way including Loops, Ramps of Interchanges and 150 mm. for
Connecting / Service / Slip Road / Approaches to VOP’s / Cross Roads at Interchanges / Grade Separator.
2.0 MATERIALS
The materials will be an approved combination of crushed stone aggregate, crusher dust and natural
sand proportionally blended to comply with clause 406.
3.0 EQUIPMENT
a) WMM plant with Pug Mill complete with volumetric control feed bins calibrated with weight and
controlled water supply for preparation of mix to required grading and moisture contents.
b) Tipper trucks for haulage to the laying site from WMM plant.
c) Laying of material by paver finisher.
d) Vibratory Roller minimum 80KN - 100 KN static weights for compaction of material to the
required finish and density.
4.0 WORK PROCEDURE
a) i) Sub - Base Preparation: The Sub- base on which the A I L / WMM is to be laid will be prepared,
conditioned to the specified lines, grades and cross – sections and tested for required field
compaction. Prior to commencement of AIL/WMM operations the underlying CTB layer (dampened if
necessary) is to be inspected.
a) ii) Preparation of Mix:
b) Guide/driving lines to be furnished indicating edge of AIL/WMM layer. Where possible, furnish
Lateral restraint using earthen shoulder build to confine AIL/WMM, if this is not possible, we can
extend width at side of layer by 100mm.
c) If laying is by paver, the paver will be Positioned with screed support equivalent to required layer
thickness (not to exceed 200mm) plus roll down allowances when starting new lane or with roll
down thickness shims when pulling away from existing cut joint. Material to be tipped directly from
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trucks into hopper.

d) If it is by grader, the A I L / WMM material shall be dumped during the nights on sub base and
the same would be graded during early morning.
e) Laying shall be started from lower end. Before laying the adjacent lane, the already laid edge shall
be water sprayed as per requirement. However, the laying may be done from higher end to
lower end to avoid obstruction to free flow of rain water.
f) In case some open graded texture is observed, the same shall be treated with 6mm down
material. Rolling to commence from low side to high side of super-elevation, overlapping each
pass by a minimum of 1/3 of roll width until full width of layer is covered.
g) Compaction to be continued until surface is free from movement, ridges, cracks and is capable of
achieving a minimum of 100% for AIL and 98% for WMM compaction as per specifications.
h) Upon completion of final rolling, area shall be cordoned off to all traffic for a minimum of 24 hours
to allow material to dry.
i) Wet Mix Macadam, area to be trafficked only by required plant for construction of upper courses.
j) Field Density tests to be carried out after compaction is completed and level Control Check
will be carried out on 2nd layer of AIL/WMM prior to approval for the application of Bituminous
Prime Coat.
k) Levels to be checked either by instrument or by dipping from previously agreed and approved
marked steel rods or block up points.
These shall be carried out as stipulated within MoRT&H clause 406.6 and 902
5.0 QUALITY CONTROL
Routine testing to be carried out as stipulated within MoRT&H 900 section.
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1.0 DESCRIPTION
This work shall consist of the procedure for application of bituminous Emulsion (SS) primer on
Granular surface/ WMM base as per clause 502.
2.0 MATERIALS
The bituminous Cationic emulsion SS-1 primer complying with IS: 8887 or medium curing cutback
bitumen conforming to IS: 217.
3.0 EQUIPMENT
a) Propelled pressure distributor complying with the requirement of Clause 502.4.1 capable of
supplying primer at specified rates and temperature to provide uniform unbroken spread of
primer.
b) Air Compressor with manual Labour to clean area to be primed.
c) Water Bowser for application of light sprinkling of water if required.
4.0 LAYING PROCEDURE AND CURING
a) Prior to commencement of priming the underlying WMM surface shall be prepared as per
clause 502.4.2(damped if necessary). Prepared surface to be inspected and approved by the IE,
ensuring weather conditions comply with clause 502.3.
b) The rate of priming shall be applied at the rate of 7.0 kg to 10.0 /10 square meters.
c) Care shall be taken not to over – prime leaving pools of excess primer.
d) Following application of bituminous primer, a minimum of 24 hours curing shall be allowed to
enable penetration of binder and escape of volatiles. No traffic of any kind is permitted upon the
primed surface. Barriers to be erected as required to prevent unauthorized egress.
e) If applied primer is not absorbed after 24 hours of application, sand shall be spread over the
surface to blot excess primer, any residue pools being swept over adjacent surfaces prior to
spreading sand.

These shall be carried out as stipulated within MoRT&H clause 502.4.2 and 902.
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6.0 QUALITY CONTROL

Routine testing to be carried out as stipulated within MoRT&H Table 900- 4.
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1.0 DESCRIPTION
This work shall consist of the procedure for application of bituminous Emulsion (RS 1) Tack Coat on
Existing Bituminous road surface as per clause 503.
2.0 MATERIALS
The bituminous Cationic emulsion RS tack coat complying with IS: 8887.
3.0 EQUIPMENTS
a) Propelled pressure distributor complying with the requirement of Clause 502.4.1 capable of
supplying tack at specified rates and temperature to provide uniform unbroken spread of tack coat.
b) Air Compressor with manual Labour to clean area to be tack coat.
4.0 LAYING PROCEDURE
a) Prior to commencement of tack coat the underlying existing bituminous surface or granular
surfaces treated with primer shall be prepared as per clause 501.8. Prepared surface to be
inspected and approved , ensuring weather conditions comply with clause 503.3
b) The rate of tack coat shall be applied at the rate of 2.0 to 3.0kg/10 square meters on bituminous
surface, and 2.5 to 3.0 kg/10 square meters on granular surfaces treated with primer.
c) Care shall be taken not to over – tack leaving pools of excess tack coat.
d) The tack coat shall be left to cure until all the volatiles have evaporated before any subsequent
construction is started. No traffic of any kind is permitted upon the tacked surface other than those
essential for the construction. Barriers to be erected as required preventing unauthorized egress.
5.0 QUALITY CONTROL
Routine testing to be carried out as stipulated within MORT&H Table 900- 4
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REV. Date : 06.02.2023
(Package-I).
1.0 DESCRIPTION
Methodology for laying of DBM in this project is detailed herein under. This method statement is based
on parameters conforming to MoRT&H, MS-2 Specifications.
2.0 MATERIALS
a) Bituminous material Penetration of paving bitumen of VG 40 shall confirm to the specifications of IS:
73.
b) Aggregate and filler shall confirm to the specification of MoRT&H.
3.0 PLANT & EQUIPMENT
a) Batch type hot mix plant.
b) Self- propelled paving machine having tamping/vibrating extendible screed and meeting the
requirement as to Clause 501.5.
c) Tandem Vibratory Rollers.
d) Pneumatic Tired Roller, 150 to 250 KN weigh having at minimum tire pressure of 0.7 MPA.
e) Bitumen sprayer with all accessories as pr Clause 502.4.1.
f) Sufficient number of tippers for continuous laying.
4.0 WORK PROCEDURE
4.1 Preparation of base: -
The base on which the DBM is to be laid will be prepared, conditioned to the specified lines, grades
and cross – sections and tested for required field compaction. The surface will be thoroughly swept
clean free from dust and foreign matter using compressed air.
4.2 Pr e p a r a ti on of Mix: -
Appropriate job mix of dense graded bituminous Macadam mix will be prepared in a hot mix
plant of adequate capacity and capable of yielding a mix of proper and uniform quality with
thoroughly coated aggregate. The temperature of binder at the time of mixing will be in the
range of 160 0C to 170 0C and that of the aggregate in the range of 160 0C to 175 0C. The
difference in temperature between the binder and aggregate will be maintained at less than 14
0C. The mixing will be thorough to ensure that a homogeneous mixture is obtained in which all
particles of aggregate are coated uniformly and the discharge temperature of mix will be
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REV. Date : 06.02.2023
(Package-I).
maintained between 160˚C to 170˚C.

4. 3 Sp r e a d i n g & co m p a c ti n g of DB M
a) Prior to commencement of DBM course operation the underlying layer of previously laid
primed Base course is to be inspected and approved by the IE Representative.
b) Guide lines to be furnished where applicable, i.e. edge of pavement, across side roads,
median opening etc.
c) The mix shall be prepared in approved plant and transported to laying site as per clause
501.3 and 501.4
d) When laying against transverse/longitudinal cold joints these to be cut vertically and painted
with bitumen emulsion.
e) Position paver with screed supports equivalent to required layer thickness plus roll down
allowance, when starting new lane or with roll down thickness shims when pulling away from
existing transverse cut joints. Paver screed width is to be pre-set to laying pattern widths prior to
positioning.
f) Recommended compacted Layer thickness will be maintained across the mat with sensor
controls.
g) If the Compacted layer thickness is lies in between 75mm to 100mm, Grading I Job mix will
be used, if lies in between 50mm to 75mm Grading II job mix will be used. If more than 100
mm thickness number of layers will be adjusted accordingly.
h) All water spray bars and mats on steel wheel rollers to be checked by operators and fully
working prior to commencement of lay down.
i) Material t o be tipped directly into paver hopper and screed box suitably filled to
extremities prior to starting laydown, temperature of material being minimum of 1500 C and
maximum of 1700 C.
j) When pulling away from existing joints, care to be taken that sufficient material is against the
joint. This area will be requiring handwork with raking and additional material to ensure a flush
joint with earlier laid pavement as the joint is initially compacted.
k) When tying into a cut longitudinal joint the newly laid the newly laid material will be higher than
existing. This is to be dressed at all times and controlled Operators are NOT required to walk on
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REV. Date : 06.02.2023
(Package-I).
the freshly laid mat, all hand works are edges of the mat. Walking upon the mat will leave
visible marking after rolling but also affect compliance with the requirement of surface regularity.
l) Check dipping shall be carried out by screw men to check depth of laying after screed
before rolling. Rolling shall commence with the initial breakdown roller when the material is
sufficiently cool to be rolled without cracking or pick up a previously determined in earlier
JMF trails(s). Dependent on whether the mat is the initial or second strip the roller shall
commence rolling from low side to high, leaving an un-compacted strip of approximately 150mm
width on the low side if longitudinal hot jointing is to be employed. Application of water to rolls
shall be kept to a minimum. All out efforts shall be made to lay continuously, to avoid bumps
at every stop of paver for want of materials. Speed of paver to be reduced as required to
ensure continual laying. Dependent on JMF laydown trail(s) intermediate rolling shall be done
by either 8 - 10T steel wheeled rollers or by PTR. Check dipping to be carried out by Screw men
to ensure depth is met after rolling.
m) During process rollers are NOT to stand /park on the hot mat.
n) Rolling shall continue until compaction is achieved to the requirements of the
specification and all the rollers’ marks are eliminated by finish roller. Density checking utilizing
NDT to control compaction following appropriate trail(s).
o) Upon completion of rolling, no traffic is allowed on the finished surface until the material has
cooled to ambient temperature. Only rollers are to traffic the mat when laying adjacent lanes
whilst laying against the longitudinal hot joints. Areas to be protected against unauthorized
entry by vehicles.
p) Following completion of laying operations all machinery to be parked off construction layers
to avoid damage whilst being serviced and provisioned for following operations.
5.0 QUALITY CONTROL

Routine testing to be carried out as stipulated within MoRT&H Clause. 903 table 900-4 and reduced to
acceptable levels during continuous production from established stockpiles reference aggregates
properties.
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REV. Date : 06.02.2023
(Package-I).
a) Quality Control tests for bitumen shall be done for every lot.
b) NDT to be used in determination for compaction rates achieved to further the use of Non-
Destructive Testing and reduction of coring correlation purpose only.
6.0 ADDITIONAL ITEMS
a) Spreading of material with in restricted areas and narrow widths will be carried out by manual
laying.
b) When hot jointing longitudinal joints paving shall be set back into adjacent lane and
commence paving before earlier laid material has cooled to 1000 C, performance of material
at the joint will be mentioned.
c) Laydown of material shall not be carried through standing water, any puddles to be
removed prior to placing of materials,
d) In the event of rain occurring during operations laydown is to cease when it is apparent water
is standing on surface, to this point material within hoppers is to be minimized and rollers shall
continue with their compaction works. All wagons shall have their tarpaulins securely fastened
and fixed as to shed water off the mixed during rainy weather.
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REV. Date : 06.02.2023
(Package-I).
1.0 DISCRIPTION
This method statement outlines the procedure for the providing and laying Bituminous Concrete/AC
Wearing course accordingly to the drawings after appropriate trail(s) on a previously prepared and
approved base as per Clause 507.
2.0 MATERIALS
The materials will be an approved combination of aggregates and VG grade Bitumen or Modified
Bitumen (PMB / CRMB) conforming with the requirement of MoRT&H Clause 507 inclusive of Tables 500-
16,500-17, 500-18 and SP-53-2002.
3.0 EQUIPMENT
a) Hot mix plant.
b) Self propelled paving machine having tamping/vibrating extendible screed and meeting the
c) Vibratory Tandem Rollers.
d) Pneumatic Tyred Roller, 150 to 250 KN weigh having at minimum tyre pressure of 0.7 MPA.
4.0 CONSTRUCTION PROCEDURES

a) Prior to commencement of AC wearing course operation the underlying layer of
previously laid DBM Base course is to be inspected and approved by the IE
Representative.
median opening etc.
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REV. Date : 06.02.2023
(Package-I).
501.3 and 501.4
d) When laying against transverse/longitudinal cold joints these to be cut vertically and
painted with bitumen emulsion.
allowance when starting new lane or with roll down thickness shims when pulling away from
existing transverse cut joints. Paver screed width is to be pre-set to laying pattern widths prior
to positioning.
f) Layer thickness will be maintained as per drawing across the mat with out sensor controls.
g) All water spray bars and mats on steel wheel rollers to be checked by operators and fully
h) Material to be tipped directly into paver hopper and screed box suitably filled to
extremities prior to starting lay down, temperature of material being minimum of 1500 C and
maximum of 1700 C.
i) When pulling away from existing joints, care to be taken that sufficient material is against the
joint. This area will be require handwork with raking and additional material to ensure a flush
joint with earlier laid pavement as the joint is initially compacted. When tying into a cut
longitudinal joint the newly laid the newly laid material will be higher than existing. This is to be
dressed at all times and controlled. Operators are NOT required to walk on the freshly laid mat,
all hand works are at edges of the mat.
Walking upon the mat will leave visible marking after rolling but also affect compliance with the
requirement of surface regularity.
j) Check dipping shall be carried out by screw men to check depth of laying after screed
before rolling.
Rolling shall commence with the initial breakdown roller when the material is sufficiently cool to
be rolled without cracking or pickup a previously determined in earlier JMF trails(s).
Dependant on whether the mat is the initial or second strip the roller shall commence
rolling from low side to high, leaving an uncompacted strip of approximately 150mm width
on the low side if longitudinal hot jointing is to be employed. Application of water to rolls shall
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REV. Date : 06.02.2023
(Package-I).
be kept to a minimum.
All out efforts shall be made to lay continuously, to avoid bumps at every stop of paver for want
of materials. Speed of paver to be reduced as required to ensure continual laying.
k) Dependent on JMF laydown trail(s) intermediate rolling shall be done by either 8 – 10T steel
wheeled rollers or by PTR. Check dipping to be carried out by screwmen to ensure depth is
met after rolling.
l) During process rollers are NOT to stand /park on the hot mat.
m) Rolling shall continue until compaction is achieved to the requirements of the
specification and all the rollers marks are eliminated by finish roller. Density checking utilizing
n) Upon completion of rolling, no traffic is allowed on the finished surface until the material has
whilst laying against the longitudinal hot joints and areas to be protected against unauthorized
entry by vehicles.
o) Following completion of laying operations all machinery to be parked off construction layers
to avoid damage whilst being serviced and provisioned for following operations.
5.0 QUALITY CONTROL
Routine testing to be carried out as stipulated within MoRT&H Clause 903 table 900-4 and reduced
to acceptable levels during continuous production from established stockpiles reference aggregates
properties.
Quality Control tests for bitumen shall be done for every lot.
NDT to be used in determination for compaction rates achieved to further the use of Non

laying.
commence paving before earlier laid material has cooled to 1000 C, performance of
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REV. Date : 06.02.2023
(Package-I).
material at the joint will be mentioned.

c) Lay down of material shall not be carried through standing water, any puddles to be
d) In the event of rain occurring during operations lay down is to cease when it is apparent
water is standing on surface, to this point material within hoppers is to be minimized and rollers
shall continue with their compaction works.
All wagons shall have their tarpaulins securely fastened and fixed as to shed water off the
mixed during rainy weather.
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REV. Date : 06.02.2023
(Package-I).
1.0 DESCRIPTION
This Method Statement outlines the procedures for the providing and laying of MoRT&H Clause 515 &,
Clause 2700 Stone Matrix Asphalt in a single layer.
2.0 MATERIALS
The materials will be approved combination of aggregates, bitumen and Pelletized Cellulose Fiber’s
conforming with the requirement of CL 515 inclusive of Table 500 -1, 500-35, 500-36, 500-37, 500-38,
Clause 515.2.6 and IRC: SP 79
3.0 EQUIPMENT
a) Hot mix plant.
b) Self propelled paving machine having tamping/vibrating extendible screed and meeting the
c) Vibratory Tandem Rollers.
d) Pneumatic Tyred Roller, 150 to 250 KN weigh having at minimum tyre pressure of 0.7 MPA.
a) Prior to application of S t o n e M a t r i x A s p h a l t the underlying layer of D B M is to be
inspected and approved and Tack Coat to be applied as required in Clause 503.
median opening etc.
501.3 and 501.4
d) When laying against transverse/longitudinal cold joints these to be cut vertically and
painted with bitumen emulsion.
allowance when starting new lane or with roll down thickness shims when pulling away from
existing transverse cut joints. Paver screed width is to be pre-set to laying pattern widths prior
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REV. Date : 06.02.2023
(Package-I).
to positioning.
f) Layer thickness will be maintained as per drawing across the mat with out sensor controls.
g) All water spray bars and mats on steel wheel rollers to be checked by operators and fully
h) Material to be tipped directly into paver hopper and screed box suitably filled to
extremities prior to starting lay down, temperature of material being minimum of 1500 C and
maximum of 1700C. In case of modified bitumen used for mix the temperature of mixing shall be
higher than the conventional bitumen.
i) When pulling away from existing joints, care to be taken that sufficient material is against the
joint. This area will be require handwork with raking and additional material to ensure a flush
joint with earlier laid pavement as the joint is initially compacted. When tying into a cut
longitudinal joint the newly laid the newly laid material will be higher than existing. This is to be
dressed at all times and controlled. Operators are NOT required to walk on the freshly laid mat,
all hand works are at edges of the mat.
Walking upon the mat will leave visible marking after rolling but also affect compliance with
the requirement of surface regularity.
j) Check dipping shall be carried out by screw men to check depth of laying after screed
before rolling.
Rolling shall commence with the initial breakdown roller when the material is sufficiently cool
to be rolled without cracking or pickup a previously determined in earlier JMF trails(s).
Dependent on whether the mat is the initial or second strip the roller shall commence
rolling from low side to high, leaving an uncompacted strip of approximately 150mm width on
the low side if longitudinal hot jointing is to be employed. Application of water to rolls shall be kept
to a minimum.
All out efforts shall be made to lay continuously, to avoid bumps at every stop of paver for
want of materials. Speed of paver to be reduced as required to ensure continual laying.
k) Dependent on JMF laydown trail(s) intermediate rolling shall be done by either 8 – 10T steel
wheeled rollers or by PTR. Check dipping to be carried out by screwmen to ensure depth is met
after rolling.
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REV. Date : 06.02.2023
(Package-I).
l) During process rollers are NOT to stand /park on the hot mat.
m) Rolling shall continue until compaction is achieved to the requirements of the
specification and all the rollers marks are eliminated by finish roller. Density checking utilizing
n) Upon completion of rolling, no traffic is allowed on the finished surface until the material has
whilst laying against the longitudinal hot joints and areas to be protected against unauthorized
entry by vehicles.
o) Following completion of laying operations all machinery to be parked off construction layers to
avoid damage whilst being serviced and provisioned for following operations.
7.0 QUALITY CONTROL
Routine testing to be carried out as stipulated within MoRT&H Clause 903 table 900-4 and reduced
to acceptable levels during continuous production from established stockpiles reference aggregates
properties.
Quality Control tests for bitumen shall be done for every lot.
NDT to be used in determination for compaction rates achieved to further the use of Non
laying.
commence paving before earlier laid material has cooled to 1000C, performance of
material at the joint will be mentioned.
c) Lay down of material shall not be carried through standing water, any puddles to be
d) In the event of rain occurring during operations lay down is to cease when it is apparent
water is standing on surface, to this point material within hoppers is to be minimized and rollers
shall continue with their compaction works.
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REV. Date : 06.02.2023
(Package-I).
e) All wagons shall have their tarpaulins securely fastened and fixed as to shed water off the
mixed during rainy weather.
f) In the event of rain occurring during operations, lay down of fresh material to cease
immediately with all Care being taken to finish previously placed, material to formed joint.
g) No Stone Matrix Asphalt is to be placed upon wet or damp base .and When the air
temperature less than 100C for conventional bitumen & 150C for Modified bitumen
h) Also SMA is not to be placed when wind speed above 40km./ hrs. at 2m. height if any
temperature
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REV. Date : 06.02.2023
(Package-I).
1.0 DESCRIPTION
This Method Statement outlines the procedures for the providing and laying of MoRT&H Clause 516 &,
Clause 2700 Bitumen Mastic in a single layer.
2.0 MATERIALS
The materials will be approved combination of aggregates and bitumen’s conforming with the
requirement of CL 516 inclusive of Table 500 -1, 500-39, 500-40, 500-41 and 500-42
3.0 EQUIPMENT
a) Bitumen Mastic Cooker with mechanical agitation system mounted on wheels.
b) Bituminous Tack Coat with hand sprayer.
c) Wooden spreading and finishing floats.
d) Wooden forms.
e) Heavy duty Mastic pouring buckets/barrows as required.
f) Hand hammers
g) Generator

a) Prior to application of Bitumen Mastic the underlying layer of BC is to be inspected and
approved and Tack Coat to be applied as required in Clause 503.
b) Wooden forms shall be used as materials thickness retainers and level control to allow width of
approximately 1.0 m to be laid.
c) The Bitumen Mastic shall be Pre-heated and continually mixed up to temperature of between
1700 C to 2100 C as indicated within CL 516.4.4 throughout the laying operation.
d) Bitumen Mastic at around 1700 C to 2100 C to be decanted into Mastic Pouring

Bucket/Barrow and Poured directly onto the prepared surface within the strip and spread
uniformly by use of Wooden floats to form thickness against abutting mastic layer or wooden
forms.
e) Materials shall be poured and spread carefully as not to entrap any air within the mix.
f) When jointing against previously placed material the existing face to be pre-heated by use of
gas torches prior to jointing. Where preheating is not used excess Bitumen Mastic to be
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REV. Date : 06.02.2023
(Package-I).
applied over the joint to warm up existing material.

g) Following the leveling of the mix and finishing of joints, application of pre-coated stone
chipping prepared to the requirements of CL 516.4.5 is carried out upon the surface when the
material is at temperature of between 175 to 2100 Centigrade, the chips being pressed into
surface of the mastic layer with hand hammer.
h) The laying pattern shall be started at the point farthest away from the mastic cooker and
continued across the area to be covered, ensured that there s no requirement for Hot Mastic to
be carried over previously finished surfaces.
i) Any Mastic split upon base is to be removed prior to hardening.
j) Upon completion of laying, any Bituminous Mastic remaining in the cooker is to be poured
into moulds of approximately 25 kg weight for later use the Mastic Cooker being totally
emptied. Prior to reuse a batch sample shall be reheated to 1750 C – 2100 C and proved to
comply with requirements.
k) Trafficking of finished surface allowed only after full width is completed and the Bituminous
Mastic has cooled down to ambient temperatures. No heavy equipment is to be parked upon
finished Bituminous Mastic Course.

These shall be carried out as stipulated within CI. 902.5 reference to the Final levels.
6.0 QUALITY CONTROL

Routine testing to be carried out as stipulated within MoRT&H Clause 903.1, Table 900-4

a) In the event of rain occurring during operations, lay down of fresh material to cease
immediately with all Care being taken to finish previously placed, material to formed joint.
b) No Bituminous Mastic is to be placed upon wet or damp base.
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REV. Date : 06.02.2023
(Package-I).
1.0 DESCRIPTION
This work shall consist of constructing cement concrete kerbs in the central median and/or along the
footpaths or separators in conformity with the lines, levels and dimensions as specified in the drawings.
2.0 MATERIALS
Kerb shall be provided in cement concrete of Grade M20 or as per drawings in accordance with
MoRT&H section 1700 of these specifications.
3.0 PLANT & EQUIPMENT

a) Batching plant
b) Transit mixer
c) 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 honeycombs, shall be used.
d) Concrete cutting machine.
4.0 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 and easily accessible. In those situations,
precast concrete blocks shall be used and jointed at site.
5.0 CONSTRUCTION OPERATION

5.1 Before laying of the kerb or kerb P C C the surface will be checked and if any loose material
available, that will be removed.
5.2 Surveyor will give line, level and layout as per approved drawing before starting of the job.
Sensor rope will be set accordingly.
5.3 Kerb will be laid on WMM / DLC as per the convenience on the carriageway and on PCC in the old
carriageway as per drawing of the cement concrete of M20 grade or specified grade concrete 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 leveled and
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REV. Date : 06.02.2023
(Package-I).
slightly watered to make it damp.

5.4 Alternatively to save time the kerb can be cast monolithic with M20 concrete. Concrete will be
transported through transit mixers up to the kerb machine. Required slump will be maintained i.e 10
mm to 20mm for the concrete depending on the distance the transit mixers have to cover.
5.5 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 super elevated portions), there shall be sufficient gap/recess left in the kerb to facilitate drainage
openings.
5.6 After laying the kerbs cut grooves shall be provided at every 5 mts intervals or as specified by the
IE with the help of cutting machine.
5.7 Vertical and horizontal tolerances with respect to true line and level shall be ± 5 mm.
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REV. Date : 06.02.2023
(Package-I).
1.0 DESCRIPTION
The work shall consist of construction of dry lean concrete sub-base for cement concrete pavement in
accordance with the requirements of IRC-SP-49-2014 / MoRT&H clause 601 Specifications and in
conformity with the lines, grades and cross-sections shown on the drawings and after appropriate trail(s) on
a previously prepared and approved sub - base. The work shall include furnishing of all plant and
equipment, materials and labour and performing all operations, in connection with the work, as
approved.
2.0 MATERIALS
2.1 Cement: OPC 43 Grade conforming to IS: 8112
2.2 Coarse & Fine Aggregate: The aggregates shall be Conforming IS 383 and MoRT&H
clause 601.2.4
2.3 Water: Conforming to IS 456 and MoRT&H Clause 601.2.5
2.4 Fly Ash: Conforming to IS: 3812 (part: 1) and MoRT&H Clause 601.2.3
2.5 Curing Compound: Conforming to MoRT&H Clause 601.6.7
3.0 EQUIPMENTS
3.1 batching Plant
3.2 Sensor paving Finisher or Hydraulic grader
3.3 Vibratory Tandem Roller minimum 80KN - 100 KN static weight
3.4 Water Tanker
3.5 Tippers
4.0 JOB MIX FORMULA

The blended aggregate of coarse and fine aggregate shall confirm to the following gradation as per table
600-1 of MoRT&H. These shall consist of Ordinary Portland Cement of 43 grade from approved
source, to achieve the desired average compressive strength of 7 N/sq.mm at 7days. If fly ash is used, the
fly ash content in the total cementitious materials shall be maintained 15 - 30%.
The mix shall be proportioned with a maximum aggregate cement ratio of 14:1 and with minimum
cementitious content of 140 kg/cum. However the proportions of aggregate to cement can be increased
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REV. Date : 06.02.2023
(Package-I).
based on the mix and machine performance during the trail patch. Trial mixes with moisture contents of 5.0,
5.5, 6.0, 6.5 and 7.0% shall be made using the above stated cement and blended aggregates. Optimum
moisture and density were obtained by making cubes. These cubes shall be made in three layers, each layer
being compacted with electronic/pneumatic vibratory hammer of 300-400N downward force. After the
determination of moisture a set of 6 cubes shall be cast for determination of compressive strength on 3
and 7 days. If the required compressive strength is not achieved, increasing the cement shall make
trials and the above stated procedure shall be repeated to achieve the required strength. Before
production of concrete, natural moisture in the aggregate shall be determined and adjusted on day-to-day
basis.

5.1 Preparation of Mix
Approved job mix of DLC mix will be prepared in a mechanized batching plant, with weighing
balances calibrated. While mixing, moisture content shall be kept optimum +2%, to avoid the
evaporation losses.
5.2 Trial length
A trial length of 10 0 m shall be made for the full width of the pavement and rolled, by involving
at least on transverse construction joint involving hardened concrete and fresh laid concrete. The in-
situ density of the freshly laid concrete shall be determined by sand replacement method with
200mm dia density cone, by making 3 density holes at equal distances that diagonally bisects
the trial length, these shall not be made in the strip of 500mm from the edges. The average of
these shall be considered as 100%, and with this the field density of the regular work shall be
compared. The hardened concrete may be cut for 3m width in the trial length and reversed to
check the bottom surface for any segregation or honey-combing, if found necessary adjustments
shall be made in the mix design.
5.3 Transportation and placing
The plant mix concrete shall be transported by sufficient number of tipping trucks to ensure
continuous, uniform supply of concrete to feed the laying equipment. The mix shall be
protected from the weather, by covering the tippers/dumpers with tarpaulin during the transit.
The lean concrete shall be laid to the required widths, grades, camber and thickness with
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REV. Date : 06.02.2023
(Package-I).
self-propelled, electronic sensor paver. The equipment shall be capable of laying the materials in an
even manner without segregation, to the specified thickness after the compaction. The paving
machine shall have high amplitude tamping bars to give good initial compaction.
5.4 Compaction
The compaction shall commence as soon as the concrete laid and leveled to the full width till
there is no further movement under the roller and the surface is closed. Double drum smooth
wheeled vibratory rollers of 80-100kN static weight shall be used for this purpose. In addition to
the number of passes required for compaction, there shall be a pass without vibration as preliminary
pass and another at the end as final pass. The minimum dry density obtained shall be 97% of that
achieved in trial length, and at a distance of 500mm from edge it shall be 95% of that achieved in
the trial length. The final surface shall be inspected immediately, and all loose, segregated or
defective areas shall be corrected by using fresh lean concrete. Honeycombed areas, any level/
thickness deficiency and surface irregularities shall be corrected by concrete with 10mm and down
aggregates.
Special care and attention shall be exercised during compaction near joints, kerb, channels,
side forms, around gullies and manholes.
Longitudinal and transverse joints are to be provided as shown in drawings. At these joints unless
vertical forms are used, the edge shall be cut back to a vertical face where correct thickness of
compacted layer has obtained.
No heavy commercial vehicles like trucks and buses shall be permitted on the dry lean concrete
sub-base after its construction.
5.5 Curing
Covering the surface with gunny bags/ Hessian cloth, which shall be kept continuously moist
for 7days by sprinkling water, shall do curing or applied curing compound as per MoRT&H Clause
601.6.7, c)
6.0 SAFETY PRECAUTIONS

a) All tippers / tankers shall be provided with reverse horns.
b) Flagman shall be provided at all exit points of the trucks / tippers.
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(Package-I).
c) The speed of vehicles plying in the work area shall be restricted to 40kmph maximum.
d) If night work is to be carried out the area shall be sufficiently provided with lighting.
e) The tipplers when being positioned in front of the paver shall be move very slowly as per the
directions given by the supervisor or by the helper provided.
f) Check for the working condition of safety valves of air compressors, if compressed
air is being used for cleaning.

These shall be carried out as stipulated within MoRT&H clause 601.9 and 903.5
8.0 QUALITY CONTROL

Routine testing to be carried out as stipulated within IRC-SP-49-2014 / MoRT&H Clause. 903 table 900-6
and reduced to acceptable levels during continuous production from established stockpiles reference
aggregates properties.
a) Quality Control tests for Cement shall be done for every lot/ every Week.
b) NDT or sand replacement method to be used in determination for compaction rates.
c) Concrete strength: The average compressive strength of each consecutive group of 5 cubes
made in accordance with Clause 4.1 of IRC-SP-49-2014 shall not be less tha 7 MPa at 7 days.
In addition, the minimum compressive strength of any individual cube shall not be less than 5.5
MPa at 7 days.
1.0 DESCRIPTION
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(Package-I).
The work shall consist of construction of un-reinforced, dowel jointed, plain cement concrete pavement in
accordance with the requirements of MoRT&H 602 Specifications and in conformity with the lines, grades,
cross sections, design parameters, viz., thickness of pavement slab, grade of concrete, joint details etc.
shall be as shown on the drawings and after appropriate trail(s) on a previously prepared and
approved Sub - base.. The work shall include furnishing of all plant and equipment, materials and labour
and performing all operations in connection with the work, as approved.
2.0 MATERIALS
2.1 Cement: OPC 43 Grade conforming to IS: 269: 2015.
2.2 Coarse & Fine Aggregate: The aggregates shall be Conforming IS 383 and MORT&H clause
602.2.6
2.3 Water: The water shall be Conforming to IS 456 and MORT&H Clause 602.2.7
2.4 Fly Ash: Conforming to IS: 3812 (part: 1)
2.5 Admixture: The admixtures shall confirm to IS 6925 and IS 9103.
2.6 Curing compound: The material shell conform as per BS 7542 or ASTM-C-309-81 Type-2
2.7 Mild steel bars for dowels and tie bars: Dowel Bar shall be of plain mild steel conforming to
IS:432 and will have yield stress of Fe-500.
2.8 Tie bar: Tie bar shall be of TMT steel conforming to IS:1786 and will have yield stress of Fe-
500.
2.9 Pre-Molded joint filler: The Pre – molded joint filler shall be complying with the requirements
of IS:1838, and MoRT&H Clause 602.2.9.
2.10 Joint sealing compound: The joint sealing compound shall be conform to IRC:57. Hot
applied sealant shall be as per IS: 1834 or ASTM: 3406-95 and Cold poured sealant shall be as
under:
i) Poly sulphide BS: 5212 (Part II), IS:11433 (Part I)
ii) Poly urethene BS:5212
iii) Silicon ASTM 5893-04
2.11 Separation membrane: Impermeable plastic sheeting 125 microns thick transparent or white
in colour as per MoRT&H Clause 602.5
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(Package-I).
3.0 EQUIPMENTS
3.1 Batching Plant
3.2 Sensor paving Finisher
3.3 Texturing Machine
3.4 Water Tanker
3.5 Tippers
3.6 Joint Cutting Machine
4.0 JOB MIX FORMULA

The mix shall be designed as per IRC 15/ IS 10262 method and the design shall be based on the flexural
strength of concrete. The water content shall be minimum required to provide workability for full
compaction of the concrete to the required density. The maximum free water cement ratio shall be 0.45 (in
case of only OPC cement will be used). The mix shall be proportioned to give an average strength at 28
days exceeding the specified strength (4.5 Mpa) by 1.65 times the standard deviation calculated from the
flexural strength of the first 30 beams first during the trial length and then the job control test beams
(during the actual execution). The workability requirements at the batching plant and at site shall be
established by slump tests while doing trial length. A slump value of 25mm ± 15mm is reasonable for
paving.
The ratio of 7 days strength to 28 days strength shall be maintained, by testing pairs of beams and
cubes batch wise for at least six batches of trial mix.

5.1 Preparation of Mix.
The materials shall be mixed in a mechanized batching plant consisting air-conditioned centralized
control cabin, minimum 4 bins, weigh hoppers, separate scales for cement, fine and coarse
aggregate with weighing balances calibrated, aggregates being proportioned by automatic weighing
devices using load cells. The concrete ingredients shall be mixed thoroughly by a mixer with
automatic timing/alarm device to mix and discharge (in case of failure of timing/alarm device
concrete shall be mixed as per Manufacturer’s recommendations) capable of mixing to get a
homogenous mix without being segregated while discharge.
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5.2 Joints, dowel and tie bars

The location and type of joint shall be as shown in the drawings.
5.2.1 Contraction Joints
Transverse joints shall be contraction and expansion joints, cut with mechanical saw, could start
as early as 6-8 hours, i.e. initial hardening of concrete, after paving. The contraction joints shall
consist of mechanical sawn joint groove, 3 to 5mm wide and 1/4 to 1/3 depth of the slab. (The
construction joint shell consist of Mech. Sawn joint groups 3-5 mm wide and 1/4th to 1/3rd depth of
the slab thickness ± 5mm or as per drawing) The expansion joints shall consist of a joint filler
board positioned vertically with the prefabricated assemblies along the line of joint.
The dowel bars shall be mild steel with details and dimensions as indicated in the drawings. Unless
otherwise shown in the drawings the dowel bars shall be positioned at the mid depths of the
slab with suitable tools/means within ±20mm tolerances. The dowel bars shall be covered with
rd
plastic sheath for at least 2/3 from one end for contraction joint, and ½ length +50mm for
expansion joint. For expansion joints, a closely fitting cap of 100mm long shall be provided at the
sheath end. To block the entry of cement slurry between dowels and cap a compressible sponge
may be used.
The dowel bars shall be supported on cradles / chairs in pre-fabricated joint assemblies
positioned prior to the construction of slab 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.
5.2.2 Longitudinal Joints
The longitudinal joints shall be saw cut as shown in the drawings. A groove of 1/3rd the depth
of the slab may be cut after the final set of the concrete. The tie bars shall be deformed
steel bars of 5 0 0 Mpa complying to IS 1786. Tie bars shall be placed within the middle third of
the slab depth.
Tie bars in the longitudinal joints shall be made up into rigid assemblies with adequate supports to
remain firmly in position during the construction of slab.
5.2.3 Construction Joints
Transverse construction joints shall be placed whenever concreting is completed for the day’s work
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on is suspended for more than 30 minutes. These shall be provided at regular location of
contraction joints using dowel bars as stated above.
Using sealants, not before 14days of curing, in case OPC Cement used & 16days curing when fly
ash or blended cement used after construction of slab shall seal all transverse and longitudinal
joints, but prior to allowing the traffic ply on the new construction.
5.3 Separation membrane
A separation membrane of impermeable plastic sheeting 125 microns thick shall lay between
the concrete slab and the sub base by nailing with concrete nails to the lower layer. Wherever
overlap is necessary, the same shall be laid by at least 300mm. Before placing the separation
membrane the sub-base shall be swept clean of all extraneous materials using high pressure water
jetting or compressed air.
5.4 Trial length:
5.4.1 A trial length of 10 0 m shall be made for the full width of the pavement and rolled, by involving
at least one transverse construction joint involving hardened concrete and freshly lay concrete.
After the side forms are removed, edges of slabs shall be corrected wherever irregularities have
occurred by using fine concrete consisting of 1:1:2 ratio of cement, Sand, Course Aggregrate
(10mm) 1:3 ratio of cement to fine chips and aggregate.
After the final regulation of the slab and before the application of curing membrane, the
surface of the concrete shall be brush-textured at right angles to the longitudinal axis. The
Texturing Shall be done by tinning after finished concrete surface by using rectangular steel
tinies The wire brush used for this purpose shall be made of 32 gauge type wired grouped
together in tufts at 10mm centers and of width not less than 450mm.
5.4.2 The total time taken from addition of water to the mix, until the completion of surface finishing and
texturing shall not exceed 120minutes when the concrete temperature is less than 250C and
90minutes when the temperature of concrete is between 250C-300C.

5.4.3 Immediately after the surface texturing, the surface and sides shall be cured by application of
curing compound, which hardens in to impervious film with the help of mechanical sprayer. The
curing compound shall have a water retention efficiency of 90%. After 3 hours, the pavement
shall be covered with moist Hessian cloth or pond with water for at least a period of 14 days.
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5.4.4 Joints sealing: When saw cuts joints are adopted in construction, they are not made to provide the
minimum width specified in the drawings, they shall be widened subsequently by sawing before
sealing, and the width and depth are controlled by gauges. 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 requirements. The sealant shall be applied within the minimum
and maximum drying time of the primer recommended by the manufacturer. Before sealing, the
temporary seal provided for blocking the ingress of dirt, soil, etc. should be removed. A highly
compressible heat resistant paper-backed de-bonding strip as shown in 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.
5.4.5 The road may be opened for regular traffic after completion of curing period and after sealing
of joints.
5.5 Sand Patch Test (for measuring the texture depth)
The surface to be tested shall be dried; any extraneous mortar and loose material shall be removed
and swept clean, using a wire brush at right angles and parallel to the carriageway. A cylindrical
container of 25ml capacity shall be filled with sand passing 300microns sieve and retained on
150microns sieve, compacted by tapping the base and excess sand stroked off to level with the
top of cylinder. Then the sand shall be poured on the surface to be tested into a heap and
spread with the help of flat wooden disc of 64mm diameter of 1.5mm thick, 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.
The diameter of the patch shall be measured to the nearest 5mm. The texture depth of concrete
shall be calculated as follows:
Texture depth in mm = 31000/ D 2

Where D is the mean diameter of the patch.
Five such texture depth tests shall be taken along the diagonal line across the lane width at least
2m apart, between 50m points along the road. No measurement shall be taken within the 300mm
of longitudinal edges of the slab constructed in one pass.
The requirements of texture depth as per MORT&H table 600-5 are as follows:
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Required texture depth (mm)
Time of test No. of measurements Specified value Tolerances
Between 24hrs. and 7days after

the construction of the slab An average of 5 1.00 ±0.25
measurements +0.25
Not later than 6 weeks before
An average of 5
the road is opened to traffic 1.00
measurements
-0.35
6.0 SAFETY PRECAUTIONS

a) All concrete transit mixers / tippers shall be provided with reverse horns.
b) Flagman shall be provided at all exit points of the trucks / tippers.
c) The speed of vehicles plying in the work area shall be restricted to 40kmph maximum.
d) If night work is to be carried out the area shall be sufficiently provided with lighting.
e) Check for the working condition of safety valves of air compressors, if compressed air is being used
for cleaning.
f) The 1000 mm work area on the both sides of the paving area shall be kept clear of any
unauthorized person / workmen.
g) All the exposed moving parts of the joint saw cutters shall be provided with guards.
h) Hand gloves shall be used while application of joint sealants.

These shall be carried out as stipulated within MoRT&H clause 602 and 903.5
8.0 QUALITY CONTROL

Routine testing to be carried out as stipulated within MoRT&H Clause. 903 table 900-6 and reduced to
acceptable levels during continuous production from established stockpiles reference aggregates
properties.
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a) Quality Control tests for Cement shall be done for every lot/ every Week.
b) NDT or core method to be used in determination for compaction rates.
1.0 GENERAL
Stone Masonry consists of the construction of all structures or parts of structures to be composed of
rubble or stone pitching for slope protection of stream banks, embankment slopes, cutting inlets and
outlets, drain linings and other surfaces as shown in the drawings.
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2.0 MATERIALS
a) Stone shall be clean rough quarry stone, or as specified in the drawings, and shall be essentially
free from dust, clay, vegetative matter and other deleterious materials.
b) The size and thickness of the stones and / or filter material shall be as indicated in the contract.
c) Cement mortar, unless otherwise specified, shall contain I part ordinary portland cement to 3
parts fine aggregate by volume. Water shall be added to the mix to produce a suitable consistency for
the intended use, all to the specification of the IE’s Representative. The constituent materials of the
mortar shall comply with the appropriate requirement of the concession agreement.
3.0 CONSTRUCTION METHOD

a) Prior to constructing mortared rubble or stone pitching the surfaces against which it is to be
placed shall have been finished in accordance with the appropriate provisions of the contract
specification. Slopes which are to receive the stone riprap shall be graded, trimmed and filled, tamped
and screeded if necessary to final grade prior to laying. At the completion of preparation of surface a
request for Approval to place mortared rubble for stone pitching will be submitted.
b) The cut-off where indicated in the drawings shall be constructed prior to the laying of the rubble or
stone. Filter material of 150 mm thickness shall be spread on the slope if dry stone pitching is to
be laid on the slope.
c) Construction of mortared or dry rubble or stone shall commence at the lower part of each structure or
section of a structure and continue progressively upward Stone shall be laid in close contact one with
the other.
d) In the case of masonry with cement mortar, the surface against which the work is to be placed shall
be moistened with clean water a little in advance of construction, and covered with a layer of cement
mortar. Stones shall then be firmly set by hand into the mortar, densely packed against adjacent
stones and built up form a stone structure of more or less uniform thickness, which shall comply with
the drawings or specification.
e) All the while that stones are being placed, all voids or the interstices shall be packed solidly with
mortar and stone spalls. As each course is laid, the top of the joint shall be filled with mortar so that
the succeeding course can be positioned on a full bed of mortar. At the completion of a course or
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section, all joints shall be filled solidly with mortar and the joints pointed flush.
f) The surface of stones in the exposed faces and edges shall not be covered with mortar The exposed
surfaces and edges of the structures shall be constructed such that they have as large a proportion
as practicable composed of stone faces.
g) Weep holes shall be installed as shown on the drawings.
1.0 DESCRIPTION
The work shall consists of construction of shoulders on either side of pavement, median in the road dividing
carriageway into separate lanes and islands for channelizing traffic at junctions, in conformity with the lines,
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grades and cross-sections shown in the drawing or as per MoRT&H Clause 408.
2.0 MATERIALS
Materials for shoulders conforming to MoRT&H clause 305/401 & median and islands shall conforming to
MoRT&H clause 305, and sub-grade, sub- bases and wearing courses (in case of treated shoulders) and
shall conform to the physical requirements of each individual layers.
3.0 EQUIPMENTS
a) Excavator,
b) Dumpers or tippers,
c) Water Tanker,
d) Grader
e) Rollers.

a) The sequence of construction operations shall be such that the shoulders, median and
islands are done in layers each matching the adjoining pavement layers. Where the materials in
adjacent layers are different, these shall be laid together, pavement layer shall be compacted first,
later the shoulder, median or island layers are compacted.
b) In all cases where paved shoulders are to be provided along side of existing carriageway,
the shoulder shall be excavated to its full width as stated in drawings, and laid to the grade,
camber as stated in drawings.
c) Regardless of method of construction, the materials shall be placed directly on shoulders,

median and islands; any spilled material on to the pavement shall be removed, without
damage to the pavement.
d) After the surface reached to the road level, if raised, the median and islands shall be raised at
least by 300mm by using Kerb stones of approved materials.
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5.0 QUALITY CONTROL

Routine testing to be carried out as stipulated within MoRT&H section 900 and conforms to specifications.
6.0 INSPECTION AND TEST PLAN

Each fill layer to be reported and density test will be checked.
1.0 DESCRIPTION
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(Package-I).
This work will 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.
2.0 EQUIPMENTS & TOOLS

1. Hand Tools
2. Water tanker
3. Dumper
4. Wooden Formwork

a) Slope Preparation:
The compacted layers shall be trimmed to the required slope and profile as per the
approved drawing using line and pegs. Any depression shall be filled up and compacted
thoroughly using wooden rammers.
b) Placing of filter layer:
GSB material (approved as filter material) shall be placed manually over prepared
base and shall be compacted in uniform layer of 150mm maintaining slope and profile as
per the approved drawing.
c) Dry rubble pitching:
Over the prepared filter layer dry pitching shall be carried out either with stones of
specified quality having an average weight of 40 Kg maintaining slope and profile as per the
approved drawing. Pitching shall be commenced from bottom of the slope and continued to
the top. In case of rubble pitching care shall be taken to minimize void between the stones,
which however shall be filled up with spalls of suitable size.
d) Construction of chute drain:
Chute drain shall be constructed as per standard manner along the road alignment
parallel to the slope of pitching as per the dimension, slope and profile as mentioned in
approved drawing. Firstly leveling course (M10 grade) shall be placed along the
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embankment slope over filter layer and shall be extended to the Kerb face. The drain wall
shall be constructed with PCC M15 concrete. At junction of chute drain with kerb, the kerb
shall be cut to the required dimension.
e) Construction of stone masonry Toe drain:
Construction of Toe drain shall be done simultaneously with the slope pitching. Soil at toe
portion shall be trimmed, leveled and compacted to the required shape and size. Boulder of
specified quality shall be laid in CM (1:3) maintaining the dimensions, slope and profile as
mentioned in approved drawing.
f) Curing:
Curing of concrete shall be continued for 7 days by sprinkling of water.
4.0 QUALITY CONTROL

specifications.
1.0 GENERAL
The work comprises the supply and installation of reinforced concrete pipe culverts inclusive of
excavation, backfilling, jointing, bedding all in accordance with the concession agreement, MoRT&H
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(Package-I).
Section 2900 and the details shown on the drawings.

Surveyor is to be taken & Invert level is noted for the extension of pipe culverts.
2.0 MATERIALS
2.1 Reinforced concrete pipes shall be NP-4 type and conform to the requirement or otherwise
specified and shall be supplied by manufactures.
2.2 Size of pipes as shown on the drawing and conforming to the Contract specification.
2.3 A ratio of 1:2 cement mortars for jointing of reinforced concrete pipes shall conform to the
requirement of the Contract specification.
2.4 Bedding material shall consist of granular material specified in the MoRT&H Clause 2904
3.0 CONSTRUCTION METHOD

a) The quality of materials used and the manufacture of precast reinforced concrete pipes shall be
subject to inspection and approval by the Engineer.
b) The pipes shall be placed in shallow excavation of the natural ground or in open trenches cut in
existing embankment.
c) In areas of soft, spongy or unstable soil where the removal of unsuitable material is indicated in the
drawings, culverts are to be constructed at the existing ground level prior to the construction of
an embankment and in such cases the procedure shall be as follows:
The unstable material shall be excavated to such length, width and depth directed by the IE. The
excavated area shall be back filled with approved granular material compacted to give adequate
support to the pipe unless other special construction methods are indicated on the drawings. The
prepared surface shall provide a firm foundation of uniform density throughout the length of the
culvert to receive the pipe bedding
d) The granular bedding material of well graded sand or similar granular material passing 5.6 mm
sieve shall be laid on the prepared trench bottom or foundation to the height of the underside of the
pipe, forming depressions where necessary to fit the lower part of the pipe exterior for at least 10%
of its height or as shown on the drawing. The material shall be carefully compacted and the
culvert assembled and jointed to line and level.
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e) Pipe shall not be laid until foundation and the pipe class, size and length called for at each location
have been approved.
f) Concrete pipes shall be laid true to line and level, each pipe being separately aligned pipes shall
be laid from the outlet and proceeded towards inlet. In case of use of pipes with bell-mouth, the belled
end shall face upsteam. The pipes shall be fitted and matched so that when laid in work, they form a
culvert with a smooth uniform invert.
1.0 GENERAL
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The work shall consist of excavation up to required levels & dimensions as shown on the approved
drawings in all types of soils/rocks & for construction of open foundation of bridges & RCC retaining walls
and satisfactory disposal of excavated materials.
2.0 EQUIPMENTS
a) Back hoe loader or excavator for excavation of earth
b) Dumper to convey spoils
c) De watering pumps
d) Pavement breakers with connected equipment to break and cut rock.
3.0 PROCEDURE
a) The longitudinal and transverse center lines of each foundation are shall be marked on
reference pillars at safe and convenient points from excavation location, and the outline plan
dimensions shall be marked on the ground (in the dry area), in accordance with the approved
drawings.
b) If the excavation area is having stagnant/flowing water, it will b e diverted away from the
working area.
c) The excavation is to be done (In dry condition) with machinery and spoils carried to pre-determined
site.
a) Where the existing structure is to be surveyed & as per drawings partially or fully dismantled, the
measurements shall be taken jointly and approval obtained for the dismantling process.
d) Dewatering pumps are put in service if the underground water seepage is noticed for which a
sump away from the foundation point and at a lower level will be formed.
e) When the nature of soil does not permit vertical sides, necessary shoring, strutting and blanking
or cut slopes to a required angle for proper retention of sides will be provided.
f) When rock is encountered further excavation in rock will be done with pavement breakers, and if
necessary with the use of explosives as per Clause302 of MoRT&H.
g) After the foundation and substructure up to the ground level have been completed, and cured,
the pit will be back filled up to the ground level in layers of thickness not exceeding 250 mm with
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earth as per section 300 of MORT&H, and technical specifications. However, the space around the
foundation up to the top of rock strata will be filled with concrete of required grade before the soil fill
is taken up.
4.0 SAFETY MEASURES

Barricading shall be provided on the ground prior to commencement of work.
1.0 GENERAL
Concrete in the grade of M15, M20, M25, M30, M35, M40, M45 and M50 will be used in various PCC, RCC.
and PSC components. The mixes will be designed and tested before the work is commenced. The
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manufactures, transporting, placing and compaction are stated here under.
2.0 MATERIALS
a) Coarse Aggregates (20mm or 40mm graded) conforming to IS: 383, MoRT&H clause 1007
and IS: 2386
b) Sand as per IS: 383 MoRT&H clause 1008 and IS: 2386. Fineness modules to be between 2
and 3.5
c) Ordinary Portland cement 43 grade as per IS: 8112, OPC 53 grade as per IS: 12269 or
OPC 33 grade as per IS: 269 subject to suitability.
d) Water (which is clean and free from injurious amounts of substances) conforming to
MoRT&H Clause 1010 and technical specifications.
e) Concrete admixtures: conforming to requirements of IS 9103
(i) Super plasticisers.
(ii) Retarders
f) Storage & Handling: - The stipulation in Clause 1014 of MoRT&H specification.
3.0 EQUIPMENTS
a) Concrete batching /mixing plant
b) Transit truck mixers
c) Material hauling trucks
d) Concrete placer/pumps/chute
e) Electrical or petrol driven vibrators with shaft dia.25 mm, 40 mm and 60 mm.
f) Electrical form vibrators (12000 rpm).
g) De watering pumps (Diesel or electrical)
h) Shoring & shuttering materials
4.0 TESTS TO BE CARRIED OUT

a) Tests as per IS: 383,and IS: 2386 and IS: 1124 on coarse and fine aggregates.
b) Cement should be tested as per IS: 269: 2015 for OPC 43 grade,
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c) Water to be tested as per Clause No – 1010 of MoRT&H, IS: 3025 PH value should be not less than
6.
d) Temperature of concrete at the time of laying. (Not more than 400 C & not less than 50C) at the time
of deposition.
e) Slump test as per IS: 1199 for workability determination
f) Concrete cube tests as per IS: 516 for compressive strength.
5.0 FORM WORK

a) All the formwork will be subjected inspection by the IE prior to its erection. The formwork shall
be robust and strong and the joints shall be leak proof.
b) Formwork shall be of steel, marine ply or laminated plywood.
c) All materials shall comply with requirement 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 after necessary repairs. For distribution of load to the ground through staging an
appropriately designed base plate (concrete/steel) will be provided which will rest on firm sub
structure.
d) The inside surface of formwork shall be coated with a release agent supplied by approved
manufacturer to prevent adhesion of concrete to form work.
e) General arrangement for concreting of foundation Sub–Structure & Super–Structure work should
confirm MoRT&H Cl. 2103, Cl. 2203 & Cl. 2303.
6.0 PROCEDURES
a) Before commencing with the project work, samples of all constituent materials for concrete shall be
tested in the field laboratory for approval. Test certificates will be furnished to the IE, as required in
the section 1000 of MoRT&H and technical specification.
b) Design mix for various grades of concrete and for various sources of materials will be
determined by tests jointly to be carried out along with Engineer/Engineer representative / IE
representative according to 1704.2.2 of MoRT&H. The results will be submitted for approval to the IE.
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c) Advance planning will be done for every activity connected with concreting, and the
In d ep en d en t Engineer (IE) will be notified of the program in advance as stipulated in the contract.
d) When the reinforcement and formwork for any concrete lift or component is ready, the central
batching plant will be notified the date, timings, quantity and grade of concrete to be delivered at site.
On receipt of IE’s approval, the require grade concrete (according to design mix) will be produced
from batching plant/mixing plant and dispatched to site in transit mixers. The rate of dispatch will be
controlled from site by mobile phone communication, or other means. For smaller works tilting
drum concrete mixers may be used at site to produce concrete duly observing all the contract
stipulations, with the permission.
e) The concrete brought to site will be tested for slump and if found not workable for the component
being concreted super plasticisers may be used to make the mix workable. If the lead-time for the
transit truck mixer is more than an hour, retarders may be added to the mix.
f) For PCC Works six test cubes shall be taken for each component, out of which 3 cubes each will be
tested at 7 days and 28 days respectively. For Structural concrete the frequency of sampling of
concrete of each grade shall be in accordance with table 1700-9 of MoRT&H and tested
accordance with IS:516.
g) The concrete transported to site will be placed with concrete placer/pump/chute. The process is
repeated till the transit mixer is emptied, and then another transit mixer with concrete takes its place.
h) After placement of each batch of concrete in the formwork, electrical vibrators are used either of
needle type or form vibrators (for the bridge girders only) are applied to compact the concrete to the
required degree of compaction. Excess concrete sticking to the formwork or reinforcement is cleaned
out with wet gunny bags immediately. During concreting, plastic sheets are kept as standby, to cover,
if there is any chance of sporadic rainfall.
i) The vertical shutters will be removed after 24 to 48 hours of completing the concrete. Curing will
be commenced after concreting ends. If there are any minor surface deficiencies in the finish,
these will be attended to and set right. Curing will be done with cover of wet Hessian cloth for
vertical surfaces and pounding of water on horizontal surfaces. In difficult positions, manually
operated stirrup pumps etc will do continuous wetting.
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j) The bottom support and shuttering of concreted elements will be removed after the period
specified in the contract. Any surface deficiencies will be made good and duly cured.
7.0 PRECAUTIONS
a) A spare set of vibrator shall be kept as stand by
b) In case, the concreting is likely to continue beyond daylight, the generator set and floodlights shall
be checked and available at site.
c) Rebar’s, formwork, levels and setting out should be checked and got approved.
d) The horizontal layers in concrete should not exceed 450 mm. Concrete should not be dropped
freely from a height of more than 1.5m.
e) The temperature of concrete while placing in formwork should be between 50 C and 400C.
1.0 GENERAL
The work shall consist of furnishing and placing M.S. or TMT/HYSD reinforcement bars as shown on
the drawings and conforming to the contract specification.
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2.0 MATERIALS
2.1 TMT/HYSD bars shall conform to the requirements IS: 1786
2.2 M.S bars shall conform to the requirements of IS: 432 part-1
2.3 1 mm thick soft annealed wires conforming to IS: 280 shall be used for tying rebar’s. The diameter
of binding wires shall not be less than 1.0 mm.
2.4 Unloading and Stacking
a. Unloading of steel bars shall be carried out using a crane or manually
b. Storage of steel bars shall be in clean condition and above the ground surface
(according to MoRT&H Clause 1014.5).
2.5 Checking of Delivered Steel Bars and Fabric
a. Prior to unloading, the delivery notes shall be examined for the following:
(i) Manufacturer’s & Supplier’s name
(ii) Size of bars
(iii) Grade of bars
(iv) Location of delivery
(v) Name of Recipient
(vi) Mills certificates
b. Rejected bars shall be returned immediately
3.0 EQUIPMENT
Engine powered bar cutter capable of cutting bar size up to 32mm diameter
4.0 PROCEDURE
a) A bar bending yard shall be set up for storing, cutting and bending of steel reinforcement.
b) Prior to cutting, a set of bar bending schedule to the shape and dimensions shown the drawing
shall be prepared according to clause 1604 of MoRT&H.
c) Bending of bars shall conform to the requirement of as per required I.S: 2502 and to the contract
drawings.
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d) Reinforcement shall be placed and positioned in accordance with the drawings. Such that the
tolerances are within specified requirement for cover.
e) Lap splices shall be of length as per specification or as shown on drawings. Not more than 50% of
the reinforcement shall be lapped at one location.
f) Mechanical splices where required shall be used with the prior approval.
g) Concrete Cover blocks shall be provided according to stipulated in drawing.
h) The horizontal rebars shall not be allowed to sag between supports.
i) Necessary stays, blocks, metal chairs, spacers, metal hangers, supporting wires etc, or other
subsidiary reinforcement shall be provided to fix the reinforcements firmly in its correct position.
j) Rebars shall be tied with not less than 1.0mm annealed wire.
k) Welding if required shall be subject to the IE’s approval.
l) Prior to concreting steel bars shall be inspected and approved.
1.0 GENERAL
The work includes providing reinforced concrete foundation & substructure in accordance with the drawings.
2.0 MATERIALS
a) The grade of concrete shall be specified on the drawings and shall conform to the requirement
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of the concession agreement.

b) HYSD steel conforming to IS-1786 and M.S. bars grade S-240 conforming to IS-432 part-1 mild
steel.
c) Centering & Shuttering material as per requirement.
d) Elastomeric / POT – PTFE Bearing conforming to MoRT&H Clause 2005 & 2006 respectively.
e) Hessian Cloth for curing of structure.
3.0 EQUIPMENT
a) Concrete batching plant concrete mixer system.
b) Concrete chute/placer/pump for placing concrete.
c) Transit truck mixer as required to maintain continuous pour.
d) Needle vibrators (electrical or petrol drive units). Screed vibrators where required.
e) Water Tanker for curing
f) DG Set as required.
4.0 TESTS REQUIRED

a) Slumps tests for workability at site
b) Concrete test cubes for compression strength

a) The formwork for the foundations shall be fixed in position on the lean concrete layer or the rock
surface, as the case may be, after the reinforcement has been assembled true to the longitudinal
and transverse centre lines. The lines, levels, formwork and reinforcement shall be got
checked and approved.
b) The concrete for the lean mix layer and for the foundation/ substructure lift will be produced in the
batching plant as per design mix approved by the Engineer, and transported to site in transit truck
mixer, and laid in position with the chute or placer/pump. Compaction will be carried out with the
needle vibrators, except lean concrete base course, which will be trampled with rammers. Slump
tests will be done to assess the workability and the retarders or super plasticizers will be added if
required to obtain quality concrete product. Specified number of tests cubes will be taken for
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determining the 7 days & 28 days compressive strength. Vertical shutters will be removed 24 hours
after concreting, and the curing will be commenced as per specification after rectifying the surface
deficiency if any.
c) The top surface of foundation over which substructure is to be laid shall be scraped with wire brush
and all loose materials removed.
d) The formwork for the substructure shall be fixed in position after the reinforcement has been
assembled true to the line & level & approved by IE.
e) Weep holes will be incorporated in the substructure of abutments and concrete retaining walls as
shown in the contract drawings. The pier cap, abutment cap and pedastals with seat for bearings will
be concreted to the levels and dimensions shown in the drawings.
f) The locations and levels of pier / abutment cap, pedestals and bolts for fixing of bearings, shall be
checked to ensure alignment as per drawing.
g) Plank / Girder Casting Method: The procedure adopted for casting of plank / girder (RCC / PSC) is
as follows:
1. A casting bed shall be prepared on ground for casting the plank / girder.
2. Alignment, verticality and condition of formwork shall be checked prior to concrete pouring.
3. In girders, bearing dowels shall be fixed in bottom of girder.
4. Girder shall be launched as per the approved scheme with safety. Care shall be taken during
transportation of girder to work site.
5. After launching of main Girder, shuttering of cross girders are fixed and cross girder concreting
done.
h) Elastomeric bearings shall be kept in position with Epoxy mortar on top of the pedestals. The line
and levels have to be approved by the IE’s representative before concreting starts.
i) Fixing of Pot PTFE Bearing:
a) Pockets shall be left in the pedestal for fixing the dowel of bearing.
b) Top dowels of bearing shall be fixed in the bottom of girder to be placed on the bearing.
c) Adjustment of bearing as follows:
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1) Adjust the pot bearings to allow them to move when dead loads are applied. Ensure that the
bearing is properly positioned and parallel (free from rotation) after applying the dead load.
2) Adjust the bearings horizontally on the masonry plate to properly fit the superstructure
members being erected.
j) Curing will be done as per specifications. When the cube strengths attain the specified value or at the
period indicated in the specifications, the formwork will be released and taken for reuse.
6.0 QUALITY CONTROL

specifications.
1.0 PURPOSE
This document sets out the work method statement for erection of Bored Encased Pilling. In order to carry out
the work in Planned and systematic manner.
2.0 SCOPE
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To set out the requirement for Bored Encased Pilling work for Project to meet all the contract requirements and
standards for work operation, safety, quality and environmental compliance. This Method Statement applies of
section work.
This includes the following.
 Boring in soil followed by drilling into soil to designed depth.
 Reinforcement cage lowering.
 Concreting.
3.0 REFERENCE
 Contract Agreement
 IRC: SP 99
 MoRT&H, 5th Revision
 IS: 2911
4.0 EQUIPMENT LIST

Sl. No. Description of Equipment’s Quantity
1 Hydraulic Rig / Conventional Rig As required
2 DTH Machine 1 No.
3 50~70 Ton Service Crane 1 No.
4 Casing (OD & ID as per drawing) As required.
5 Welding Machine 1 Set
6 Tremie pipe with Hooper As required
5. BORED CAST-IN-SITU PILLING METHODLOGY:

Bored Encased pile installation shall be performed according to the following sequence
5.1 Survey and setting out
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The surveyor will set out the center of the bored pile location. Offset reference pegs will be established
and maintained. Datum level shall also be established and ground level measured and recorded
before commencement of any excavation work.
5.2 Utility Diversion:

After making pile layout area by Surveyor, any utilities present at site will be enquired with Concerned
departments in advance. If any Utilities found in particular pilling area will be diverted in accordance
with approved diversion plan from Concerned department.
5.3 Pile Vertically & Position:

 Vertically
The maximum permitted deviation of the finished pile from the vertical is 1 in 75.
 Position
The maximum permitted deviation at cut off level of the pile center from the center point
show on the setting out drawing shall be 75mm in any direction
During the course of boring the following checks will be made:
o Check the verticality of casing during installation by plumbing from two

perpendicular directions.
o Check the eccentricity of borehole at the casing top. The temporary steel
casing will be extracted and reinstalled until the eccentricity is within
acceptable tolerance.
o Before the boring passes the casing toe, the verticality of casing until the toe
will be checked with plum-line method, taking into consideration the
eccentricity at the top of the casing. To ensure that the resultant eccentricity
at the casing toe is within the permitted tolerance 75mm.
o Level at the top of the temporary steel casing will be taken and recorded to
enable measurement of pile depth.
5.4 Installation of Casing/Liner
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As per the design diameter liner 300mm. height shall place in location and using DTH for 150mm. dia.
5nos. holes shall board up to tip level.
Then initial used 300mm. height liner pice will be removed and design diameter, thickness & long steel
casing shall then be installed into the bore hole by lowering the casing with a crane. Verticality shall be
checked and ensure during the installation. The drilling rig is then used the progress the excavation
through Augur to the next depth. A specified long casing shall be then welded to previous inserted
casing and with the help to crane and boring machine it shall be inserted in to bore. Same procedure
shall be applied up to the hard strata. Once boring encountered to Rock strata e.i. then of following 3
methods will be applied.
Case-I
Once hard strata encountered Soil Augur will be replaced by Rock Augur and boring will be continue
upto tip level.
Case-II
If it is observed that sufficient penetration of Bore hole is not obtained then Core Cutter will be used for
achieving better penetration and reached tip level.
Case-III
If Case-I & Case-II are not sufficient for achieved tip level than conventional Bailer & Chisel method
will be applied for advancement of boring and achieved tip level of pile.
Excavation depth will be checked using a sounding chain. During boring operation, soil sample will be
taken at 5m intervals or at every change of soil strata which is earlier for soil inspection. These
samples will be stored in properly labeled plastic sampling containers on daily basis.
5.5 Cleaning of Base & Completion of Boring:

Boring will be stopped when he pile toe level has been reached. First, the base of the borehole will
then be cleaned carefully with the chisel to remove loose, disturbed or remolded soil at the base of the
borehole. The Borehole shall be washed by bentonite flushing to ensure clean bottom. Flashing of
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bentonite shall be done continuously with fresh bentonite slurry till the consistency of inflowing and
outflowing slurry is similar. The depth of the borehole must be confirmed prior to placing the
reinforcement cage.
5.6 Fabrication & Installation of Reinforcement Cage:

 Fabrication of Cages
Cutting and bending of rebar will be carried out in accordance with approved bar bending
schedule in the steel fabrication yard or on site (if sufficient space is available) and cages
fabricated. Tie wires be used to tie main bars with the links. Lapping and welding details shall be
as per approved drawing circular concrete spacers, constructed of the same concrete grade as
the bored pile, will be used to provide required concrete cover (as per approved drawing). Vertical
distance between each layer of spacer will be four (4) meter. Each layer will consist of four (4)
spacing blocks.
 Splicing Reinforcement & Installation of Cages

The reinforcement cages will be lowered into the borehole by the service crane using steel slings
and shackles. Lifting/supporting hook will be welded to main bars at the top to transfer the weight
of the cage to shackles and supporting the cage over the temporary casing for splicing another
cage on top. Cages will be spliced on site either on the fabrication bed and lowered as one cage
or above the trench. In the latter case, the lower cage will be temporarily supported at the top
during the process of splicing will be done by means of welding and rebar rings. Finally the
complete cage will rest on the founding base of the borehole or be supported from the top of the
temporary casing while the correct cover to reinforcement being assured by the concrete spacers.
5.7 Concreting:
Specified grade of concrete with slump in the range 175±25mm shall be supplied from HGIEL
batching plant. All concrete delivered shall be visually inspected and checked against delivery
note before being tested and used. Before any is started, two delivery trucks should be available
at site. Concrete shall be placed using tremie pipes. The tremie pipes (200mm dia steel pipe) are
threaded about 100mm deep both at the lower end (Threading inside) and the upper end
(Threaded outside). Tremie pipes are joined and lowered into the hole. The end of the pipe shall
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not be more then 0.6m above to the bottom of the hole to ensure that the bottom of tremie will be
covered. Then concrete shall be discharged from the delivery truck to a hopper connected to the
tremie pipes. As the level of the concrete in the borehole rises. The termies will be withdrawn
accordingly to aid the follow of concrete. Section of the tremie pipe will be dismantled from the
top as the pipe is withdrawn. During concreting, the level of concrete inside the borehole shall be
monitored either with a weighted tape or chain. If liner top is matching with cut off level of pile,
concrete will be over flow till fresh concrete appears. If liner top is quite above the cut off level,
concreting operation will be continued till its top reaches 750mm. above cut off level & it will be
ensured by measured during concrete operation.
6. QUALITY INSPECTION & CHECKING
6.1 Location & Dimensions
Sl.
Description Acceptance Criteria
No.
1 Variation of Cross Sectional dimensions ±5
2 Variation from Vertical for Vertical Piles 1 in 150
3 For Vertical Piles deviation at Pilling Platform 75mm.
Level
4 Variation of Level of Top of Piles ±25mm.
6.2 Concreting
Sl.
Name of Test Frequency Acceptance Criteria
No.
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Minm one test of every

Determine Aggregates
1 Aggregates Fraction in a
Natural Moisture
day
Minm one test of every
2 Aggregates Gradation Aggregates Fraction in a As per Concrete design mix
day
3 Workability (Slump) In every Transit Mixture 175mm. ± 25mm.
For 28 days Strength
1m3 – 5m3 – 1 Set
6m3 – 15m3 – 2 Sets
16m3 – 30m3 – 3 Sets
31m3 – 50m3 – 4 Sets 100% of Characteristic
4 Concrete Cube Test
& Strength
51m3 and above of
concrete – 4sets + 1set for
each addition 50m3 of part
thereof.
6.3 Routine Load Test

Frequency
Sl.
Total No. of Piles for the Acceptance Criteria
No. Minm No. of Test Piles
Bridge
1 Upto 50 2 Based on the settlement
2 50 - 150 3 Criteria of 12mm. for Piles
diameter upto and including
2% of Total Piles
600mm. and 2% of the pile
(Fraction number
3 Beyond 150 diameter for piles of diameter
rounded to next higher
more than 600mm. at 1.5
integer number)
times of Design Load
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1.0 GENERAL
The work includes providing reinforced concrete superstructure in accordance with the drawings.
2.0 MATERIALS
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2.1 The grade of concrete shall be specified on the drawings and shall conform to the requirement
of the contract specifications.
2.2 HYSD steel conforming to IS-1786 and M.S. bars grade S-240 conforming to IS-432 part-1 mild
steel.
2.3 Centering, Shuttering & staging material as per requirement.
2.4 Hessian Cloth for curing of structure.
3.0 EQUIPMENT
3.1 Concrete batching plant concrete mixer system.
3.2 Concrete chute/placer/pump for placing concrete.
3.3 Transit truck mixer as required to maintain continuous pour.
3.4 Needle vibrators (electrical or petrol drive units). Screed vibrators where required.
3.5 Water Tanker for curing
3.6 DG Set as required.
4.0 TESTS REQUIRED

4.1 Slumps tests for workability at site
4.2 Concrete test cubes for compression strength

b) The levels of slab bottom shall be verified by IE.
c) In case of Plank Bridge, formwork shall be fixed on planks for casting the slab. Reinforcement of slab
shall be fixed as per drawing and slab shall be casted.
d) In case of bridge having girder, arrangement shall be made for fixing slab formwork in cross girder
and in main girder. Once the slab reinforcement is ready and bound by formwork on all the sides, the
same shall be offered for inspection and upon clearance, deck slab concreting shall be done. Prior to
that, expansion joints shall be fixed on the slab.
e) After 24 hours of concreting of slab, the shuttering plates shall be stripped off leaving the
supports to the slab. The water curing/chemical curing shall start immediately after stripping of
the plates. However, the curing on the top of the slab shall be done by ponding/by spreading sand
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and water sprinkling. After 14 days of slab casting, the staging and bottom plates shall be dismantled.
f) Crash barriers and handrails, footpath, kerb etc. where required and applicable as per the
design/drawing, shall then be completed.
g) The sequence of taking up the remaining items will be as under:
(i) Placing PVC pipe ducts, forming inspection chamber, and filling with concrete (the grade of
concrete according to drawing or specified in Contract) in footpaths
(ii) Construction of dirt walls and return walls. When the curing period is over back filling behind
abutments with filter media and selected soil, and well compacted.
(iii) Approach slabs, laying lean concrete base layer, Placing reinforcement and formwork for
approach slabs and concreting to required level.
(iv) Concrete anti crash Barrier or Pre casting units of concrete handrails.
(v) Laying the wearing course as per drawing.
h) On embankment slope dry stone pitching over specified filter media and apron, will be laid wherever
indicated in the contract drawings.
i) Backfilling of structure shall be done as per standard manners.
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1.0 GENERAL
The work consists of providing and placing in position prestress steel cable in bridge superstructure
girders as shown in drawings and post tensioning them in accordance with the procedure and time schedule
specified in the contract drawings & specification.
2.0 MATERIALS
2.1 Cable & Cable sheathing shall be according to the drawings and shall conform to the
requirement of the concession agreement.
2.2 Cement grout conforming to IRC: 18-2000 Appendix –2
2.3 Cable anchorages, spacers, sheath sleeves or couplings as per manufacture’s specifications.
3.0 EQUIPMENT
3.1 Multi pull stressing jacks for the system along with hydraulic pumps and pressure gauges.
3.2 Cable sheath making machine (Alternatively sheaths may be purchased from market as
required) As per drawing & specification.
3.3 Grout pump and ancillary equipment for cement grouting of cables.
3.4 Portable strand cutter machine with circular cutting blade.
4.0 HANDLING & STORAGE

a) Pre stressing steel shall be obtained from manufacture in coils of not less than 2m dia without
breaks or joints. The protective wrapping shall be chemically neutral. The coils shall be
stored about 300mm above the ground in a covered and closed store having a single door
with double locking arrangement and no windows. The air inside shall be kept dry as far as
possible.
b) Anchorage components and sheathing material shall be handled and stored in such a way that
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there is no mechanical damage or detrimental corrosion.

c) At the time of delivery at site, the delivery notes should contain the following:
(i) Manufacturer/supplier’s name
(ii) Size and length of strands in each coil
(iii) Location and date of delivery.
(iv) Manufactures test certificates.
5.0 PROCEDURES
a) A platform will be set up in the yard near the bridge site for preparing the sheaths and cables.
b) The sheath making machine die set will be fixed on a suitable base, and the 0.4-mm thick bright
metal strip will be drawn through in to form the sheaths. They will be examined for defects, holes,
damages etc. and remedial measures, if required, will be taken. Sheaths will be cut to specify lengths
and stored over supports about 300mm above ground level. Normally sheaths will be prepared just
before their placement in girder formwork.
c) The strands of pre stress steel will be un-coiled, cut to required lengths, and arranged to rest on
the periphery of a spiral wire coil or spacer and tied together with 16 gauge wire. The tendons will be
threaded in the sheaths to form cables. This process will be carried out just before they are needed to
be placed in the girder formwork.
d) After the centering and outside formwork for the girder is erected and the end blocks are placed
in position, the HYSD reinforcement on the outer face of girder will be laid in position.
Thereafter ladders and spacers are fixed such that the cables placed on them are arranged to have a
smooth profile as shown in drawings. All joints in the sheaths and holes if any are carefully sealed
with tape to make them watertight. The un- tensioned reinforcement on the inner face is then laid,
and the inner shuttering is closed for the webs and soffit.
e) The IE’s approval will be obtained at each stage of
(I) centering erection
(II) placing reinforcement
(III) placing cables
(IV) closing shuttering
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f) Modified elongation chart is prepared follow the stressing sequence procedure as mentioned in
respected approved drawings. All cables will be prestressed in single stage, when web concrete
attains a strength of approved strength, whichever is later. Jacking force shall not exceed
approved Tonnes and shuttering shall be removed only after all cables have been prestressed
satisfactorily. Cables will be tensioned simultaneously from both the ends, in accordance with the
conditions specified on the drawings. After pre stressing is completed, the ends of tendons
projecting beyond the anchorages will be cut with mechanical cutters but only after the cables are
grouted and the grout has set.
g) 7 days after the cables are prestressed, each cable shall be cleaned with water jet under
pressure introduced through one end of the cable. When clean water starts coming out at the other
end the water jet will be withdrawn and immediately followed by cement grouting under
pressure. The grouting shall be carried out as per IRC- 18- 2000 Appendix-2.
h) The cut ends of the tendons at the face of anchorages are covered with Epoxy mortar.
Subsequently the recess housing the anchorage’s will be given a coat of epoxy and filled with fresh
cement concrete using graded 10mm size chips, and smoothly finished flush with the end face of
the girder, and dully cured.
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1.0 GENERAL
The work consists of supplying and placing in position the strip seal expansion joints. These are proprietary joints
supplied by the manufacturer holding the license for it, and the following information will be provided to the Engineer
for acceptance.
i) Name and location of the manufacturer
ii) Detailed drawings showings dimensions, general details including materials specification,
anchorage details and installation procedures.
iii) Evidence of satisfactory performance of such joints supplied by the manufacturers in the
past.
iv) The expansion joint will be provided to the full width of superstructure unit, including
the footpath and railing ends, as shown on the drawings.
2.0 MATERIALS
The Complete sets of expansion joint units will be supplied by the manufacturer, and these will be fixed in position
under the supervision of the manufacturer’s representative.
3.0 TEST CERTIFICATES

Manufacturer of the expansion joints shall produce the following test certificates:
a) Acceptance test stipulated in table 2600-1 of MoRT&H specification and for stretch testing.
b) Certificate from laboratory that the seal have been to withstand 2 x 106 load change
cycles without showing signs of damage and that anchorage system has been tested to
determine optimum configuration of the anchorage assembly under dynamic loading.
c) Water tightness under water pressure of 4 bars.
d) Evidence of satisfactory performance of the similar joints installed elsewhere in the past.
4.0 PROCEDURES
a) The strip seal expansion joints will be installed as per detailed instructions stipulated in
clause 2606 of the MoRT&H specifications
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1.0 GENERAL
Turfing is easiest and most effective way to control and reduce erosion on side slopes of cut and fill
embankment during the Construction of Highway.
2.0 TURF
All turf’s shall be cut in size not less than 300x 250 mm rectangle with sods 50 – 80 mm thick having grass at
least 50 mm long on them. They shall consist of healthy dense indigenous grass firmly rooted into at least
50mm of topsoil. The turf shall be free from objectionable plants. The area to be turfed shall be trimmed to
required slope and cross section.
3.0 PROCEDURE FOR CULTIVATION OF TURF

a) Topsoil shall be loosened and brought to a reasonably granular texture and lightly compacted to
thickness of 25mm minimum. Where required, additional topsoil shall be spread over the slopes.
b) Turf shall be delivered for use generally within 48 hours of cutting. Turfing shall be done just before
the start of rainy season.
c) The prepared areas should be wetted with water and shall be close turfed with no gaps
between the turves and lightly beaten.
d) Turf applied an the steep slopes shall be secured with wooden pegs driven into ground flush with
the top of the turf.
e) Regular watering of newly laid turf if laid during dry weather shall be done until such time as it is
firmly established
f) Alternatively turfing would be grown in sites as was done for Grass lawns.
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1.0 GENERAL
The thermoplastic paint road-marking compound shall be extruded or screeded on to the pavement surface in
a molten state by a suitable machine in controlled preparation and laying with surface application of glass
beads at a specific rate as per guidelines IRC: 35- 2015
2.0 MATERIAL
2.1 Proprietary brand of thermoplastic material of Table 800-9 of MoRT&H which is homogeneously
composed of aggregate, pigment, resins and glass reflectorizing beads (Type – 1)
2.2 Reflectorising glass beads (Type-2) of Table 800-10 of MoRT&H specification for spraying on
molten thermoplastic paint on pavement surface.
3.0 EQUIPMENT
The application shall be done by a suitable machine with a burner at the bottom for keeping the paint in
molten condition until it is applied to Road surface.
4.0 PROCEDURES
a) The road surface shall be dry and free from debris, mud and other extraneous matter.
b) The road marking alignment shall be measured and marked out with a string and chalk prior to
application of the thermoplastic paint.
c) Thermoplastic paint shall be applied by machine or manually @ 5 Kg / Sqm (where machine
cannot be used) at temperature not exceeding the limits specified by the manufacturer.
d) A further quantity of glass beads will be applied onto the hot marking line at the time of
operation at 250 gm /Sq.m. of area.
e) Thermoplastic paint shall be applied to a thickness of at least 2.5 mm.
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1. GENERAL
Methodology for laying of CTSB shall be prepared by Mixing Plant or by In-Situ Mixing and it is detailed as
under. This method statement is based on parameters confirming to MoRT&H, Specifications and IRC Codes.
2. MATERIALS
 CTSB Materials shall confirm to IRC: 37:2018 / MoRT&H & IRC: SP-89:2018.
 Recommended Aggregate gradation for CTSB shall be as per MORT&H, Table400-1, G-4.
IS Sieve (mm) % of Passing

53.0 mm 100
26.5 mm 50-100
4.75 mm 15-35
0.075 mm 0-5
3. PLANT AND EQUIPMENTS

 Mixing Plant : 01 Number
 Wheel Loader for loading the hoppers of plant : 04 Number
 Paver/Motor Grader (Grade Control 3D System) : 2 No. as a minimum
 Dumpers / Tippers : 25 No. as a minimum
 Vibratory/Tandem Roller of 80-100kN : 3 No. as a minimum
 Water Sprinkler : 3 No. as a minimum
 Cement Spreader : 01 Number
 Mixing/Milling Machine (WR 240) : 01 Nos
4. SETTING OUT OF CROSS SECTIONS

Setting out will be carried out in accordance with approved drawings. Required cross-sections will
be maintained as per approved drawings.
Cross sections as submitted on the basis of approved survey details and approved construction
drawings shall be used to execute the work.
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5. CONSTRUCTION OPERATION
The execution of CTSB of 200mm thickness will be executed at site in the following manner.
i) CTSB shall be prepared in an approved mixing plant of suitable capacity having controlled
addition of water and mixing arrangement like pug mill or pan type mixer of WMM plant or for Mix
on site for cement spreading a suitable Cement Spreader should be used with a specialized
purpose made machine for mixing (WR 240), as recommended in IRC SP 89 (2018) Annexure IV.
ii) Optimum moisture for mixing shall be determined in accordance with IS: 2720 (Part-8).
iii) At the time of compaction, water in the mix should not vary from the optimum value -2% and
+1%.
iv) The mix may be laying in two half parts either by a Paver/motor Grader Finisher. The Paver/
motor Grader Finisher shall be capable of spreading the material uniformly all over the
surface.
v) The paver/ motor Grader finisher shall be self-propelled, having features.
vi) No segregation of larger and fine particles should be allowed. The mix as spread should be
of uniform gradation with no pockets of fine material.
vii) After the mix has been laid to the required thickness, grade and cross fall / camber the same
shall be uniformly compacted, to the depth with suitable roller.
viii) If the thickness of single compacted layer does not exceed 200 mm, a smooth wheel roller of
80 to 100 KN weight may be used.
ix) If portion having unidirectional cross fall / super elevation, rolling shall commence from the
lower edge and progress gradually towards the upper edge. Thereafter, roller should progress
parallel to the center line of the road, uniformly over-lapping each proceeding track by at least
one third width until the entire surface has been rolled.
x) In portion in camber, rolling should begin at the edge with the roller running forward until the
edges have been firmly compacted.
xi) The roller shall then progress gradually towards the centre parallel to the centre line of the
road as said above.
xii) Rolling should not be done when it causes a wave-like motion in the sub-base course.
xiii) Rolling shall continue till the density achieved is at least 98% of the maximum dry density for
the material as determined by the method outlined in IS: 2720 (Part-8).
88

REV. Date : 06.02.2023
(Package-I).
xiv) After completion, the surface of any finished layer shall be well-closed, free from movement
under compaction equipment. Extreme care will be taken to see that the compaction of CTSB
material is completed with in two hours of its mixing.
6. CURING
a) After the completion of the work of final layer, the area will be closed and will not be allowed to
movement of traffic. The cemented sub-base shall be cured for a minimum of three days before the
construction of the next layer.
b) In case sufficient strength of cementitious sub-base is not achieved as per the requirement of IRC
SP:89 in 3 days of curing, 7 days curing shall be done for sub-base before the construction of the
upper layer can be started.
7. TRAFIC MANAGEMENT
 During the period of construction, arrangements for traffic shall be provided and maintained in
accordance with Clause 112 of MORT&H.
8. SAFETY
 We shall take adequate precaution against water pollution and generation of dust during the
operation.
 Workmen, Engineers, Supervisors and Inspectors associated with the operation shall wear safety
attires.
 The area where activity of CTSB is to be carried out will be properly barricaded using proper
barricades, reflecting tapes and led properly to the barricading pillars.
89

REV. Date : 06.02.2023
(Package-I).
9. GENERAL
Methodology for laying of CTB shall be prepared by Mixing Plant or by In-Situ Mixing and it is detailed as
under. This method statement is based on parameters confirming to MoRT&H, Specifications and IRC Code
10. MATERIALS
 CTB Materials shall confirm to IRC: 37:2018 / MoRT&H & IRC: SP-89:2018.
 Recommended Aggregate gradation for CTB shall be as per MORT&H, Table 400-4.
IS Sieve (mm) % of Passing

53.0 mm 100
37.5 mm 95-100
19 mm 45-100
9.5 mm 35-100
4.75 mm 25-100
0.600 mm 8-65
0.300 mm 5-40
0.075 mm 0-10
11. PLANT AND EQUIPMENTS

 Mixing Plant : 01 Number
 Wheel Loader for loading the hoppers of plant : 04 Number
 Paver/Motor Grader (Grade Control 3D System) : 2 No. as a minimum
 Dumpers / Tippers : 25 No. as a minimum
 Vibratory/Tandem Roller of 80-100kN : 3 No. as a minimum
 Water Sprinkler : 3 No. as a minimum
 Cement Spreader : 01 Number
 Mixing/Milling Machine (WR 240) : 01 Nos
12. SETTING OUT OF CROSS SECTIONS

Setting out will be carried out in accordance with approved drawings. Required cross-sections will
be maintained as per approved drawings.
90

REV. Date : 06.02.2023
(Package-I).
Cross sections as submitted on the basis of approved survey details and approved construction
drawings shall be used to execute the work.
13. CONSTRUCTION OPERATION

The execution of CTB of 165 mm thickness will be executed at site in the following manner.
xv) CTB shall be prepared in an approved mixing plant of suitable capacity having controlled addition
of water and mixing arrangement like pug mill or pan type mixer of WMM plant or for Mix on site
for cement spreading a suitable Cement Spreader should be used with a specialized purpose
made machine for mixing (WR 240), as recommended in IRC SP 89 (2018) Annexure IV.
xvi) Optimum moisture for mixing shall be determined in accordance with IS: 2720 (Part-8).
xvii) At the time of compaction, water in the mix should not vary from the optimum value -2% and
+1%.
xviii) The mix may be laying in two half parts either by a Paver/motor Grader Finisher. The Paver/
motor Grader Finisher shall be capable of spreading the material uniformly all over the
surface.
xix) The paver/ motor Grader finisher shall be self-propelled, having features.
xx) No segregation of larger and fine particles should be allowed. The mix as spread should be
of uniform gradation with no pockets of fine material.
xxi) After the mix has been laid to the required thickness, grade and cross fall / camber the same
shall be uniformly compacted, to the depth with suitable roller.
xxii) If the thickness of single compacted layer does not exceed 165 mm, a smooth wheel roller of
80 to 100 KN weight may be used.
xxiii) If portion having unidirectional cross fall / super elevation, rolling shall commence from the
lower edge and progress gradually towards the upper edge. Thereafter, roller should progress
parallel to the center line of the road, uniformly over-lapping each proceeding track by at least
one third width until the entire surface has been rolled.
xxiv) In portion in camber, rolling should begin at the edge with the roller running forward until the
edges have been firmly compacted.
xxv) The roller shall then progress gradually towards the centre parallel to the centre line of the
road as said above.
91

REV. Date : 06.02.2023
(Package-I).
xxvi) Rolling should not be done when it causes a wave-like motion in the sub-base course.
xxvii) Rolling shall continue till the density achieved is at least 98% of the maximum dry density for
the material as determined by the method outlined in IS: 2720 (Part-8).
xxviii)After completion, the surface of any finished layer shall be well-closed, free from movement
under compaction equipment. Extreme care will be taken to see that the compaction of CTB
material is completed with in two hours of its mixing.
14. CURING
c) After the completion of the work of final layer, the area will be closed and will not be allowed to
movement of traffic. The cemented base shall be cured for a minimum of three days before the
construction of the next layer.
d) In case sufficient strength of cementitious base is not achieved as per the requirement of IRC SP:89
in 3 days of curing, 7 days curing shall be done for it before the construction of the upper layer can
be started.
15. TRAFIC MANAGEMENT

 During the period of construction, arrangements for traffic shall be provided and maintained in
accordance with Clause 112 of MORT&H.
16. SAFETY
 We shall take adequate precaution against water pollution and generation of dust during the
operation.
 Workmen, Engineers, Supervisors and Inspectors associated with the operation shall wear safety
attires.
 The area where activity of CTB is to be carried out will be properly barricaded using proper
barricades, reflecting tapes and led properly to the barricading pillars.
92

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CLIENT: NATIONAL HIGHWAYS AUTHORITY OF INDIA QUALITY MANAGEMENT SYSTEM

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

27 FOUNDATION / SUB STRUCTURE 69-71

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

4.0 CONSTRUCTION PROCEDURE

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

3.2 Detailed Survey

3.2.1 REFERENCE LINE

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

3.2.2 ORIGINAL GROUND LEVEL

3.2.3 SURVEY FOR STRUCTURE

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

4.0 CONSTRUCTIION PROCEDURE

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

4.0 CONSTRUCTION PROCEDURE

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

5.0 QUALITY CONTROL

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

4.0 CONSTRUCTION PROCEDURE

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

5.0 QUALITY CONTROL

6.0 INSPECTION AND TEST PLAN

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

4.0 CONSTRUCTION PROCUDURES

5.0 RECTIFICATION OF SURFACE IRREGULARITIES

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

6.0 QUALITY CONTROL

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

trucks into hopper.

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

5.0 RECTIFICATION OF SURFACE IRREGULARITIES

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

6.0 QUALITY CONTROL

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

maintained between 160˚C to 170˚C.

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

5.0 QUALITY CONTROL

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

c) Vibratory Tandem Rollers.

e) Bitumen sprayer with all accessories as pr Clause 502.4.1.

f) Sufficient number of tippers for continuous laying.

4.0 CONSTRUCTION PROCEDURES

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

6.0 ADDITIONAL ITEMS

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

material at the joint will be mentioned.

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01

Development of Six Lane Chittoor-Thatchur Highway from km DOC. NO.: KCC/CHPL-01/CM/01